FREE CLIMBER 4400 ASSEMBLY INSTRUCTIONS · PDF fileFREE CLIMBER 4400 ASSEMBLY INSTRUCTIONS ......
Transcript of FREE CLIMBER 4400 ASSEMBLY INSTRUCTIONS · PDF fileFREE CLIMBER 4400 ASSEMBLY INSTRUCTIONS ......
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FREE CLIMBER 4400ASSEMBLY
INSTRUCTIONS
27694B
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ASSEMBLY INSTRUCTIONS
TOOLS REQUIRED:
โขCLAW HAMMER
โขKNIFE
โข1/2โ WRENCH OR SOCKET
1. USE KNIFE TO REMOVE ALL PLASTICSTRAPS FROM AROUND PALLET ANDCARTON.
STRAP
2. USE CLAW HAMMER TO REMOVESTAPLES HOLDING CARTON TO PALLET.
STAPLE LOCATION
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ASSEMBLY INSTRUCTIONS
3. REMOVE PLASTIC COVER FROMSTEPPER UNIT.
PLASTIC COVER
4. USE CLAW HAMMER TO REMOVEWOODEN BLOCKS FROM PALLET. USEKNIFE TO REMOVE TYRAPS.
TYRAPS
WOOD BLOCKS
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ASSEMBLY INSTRUCTIONS
5. REMOVE HANDLE ASSEMBLY ANDTWO BUBBLE PACKS FROM PALLET.
BUBBLE PACKS
HANDLE ASSEMBLY
6. REMOVE PROTECTIVE WRAP FROMHANDLE ASSEMBLY AND LAY ASIDE FORFUTURE INSTALLATION.
PROTECTIVE WRAP
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ASSEMBLY INSTRUCTIONS
7. OPEN SMALL BUBBLE PACK, ITCONTAINS THE CONSOLE, MAGAZINERACK, PLASTIC BAG OF HARDWARE, ANDSPACER.
CONSOLE
MAGAZINE RACK
BAG OF HARDWARE
SPACER
8. OPEN LARGE BUBBLE PACK, ITCONTAINS THE LEFT AND RIGHT UPPERCOVERS.
UPPER COVERS
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ASSEMBLY INSTRUCTIONS
9. OPEN PLASTIC BAG OF HARDWAREAND EMPTY CONTENTS.
PLASTIC BAG
10. THE PLASTIC BAG CONTAINS FOURBOLTS AND 4 FLAT WASHERS. SLIDE THEFLAT WASHER OVER THE BOLT.
BOLT
FLAT WASHER
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ASSEMBLY INSTRUCTIONS
11. THE PLASTIC BAG ALSO CONTAINSFOUR SCREWS, FOUR LOCK WASHERS,AND ONE RUBBER GROMMET. SLIDELOCK WASHER OVER SCREW THREADS.THE PLASTIC RIVETS ARE REQUIRED TOSECURE THE UPPER COVERS.
SCREW
LOCK WASHER
GROMMET
12. UNCOIL CABLE FROM AROUNDFRAME NECK.
FRAME NECK
CABLE
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ASSEMBLY INSTRUCTIONS
13. GET HANDLE ASSEMBLY AND RUBBERGROMMET, SLIDE GROMMET OVERHANDLE. SLIDE HANDLE ASSEMBLY INTOFRAME NECK. NOTE ORIENTATION OFRUBBER GROMMET.
RUBBER GROMMET
NECK FRAME
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ASSEMBLY INSTRUCTIONS
14. MAKE SURE THAT THE HANDLE ISPOSITIONED SO THE UPPER HANDLEPORTION IS PERPENDICULAR TO THEFLOOR
UPPER HANDLE
15. GET THE FOUR BOLTS AND FLATWASHERS, ALIGN HOLES IN HANDLEASSEMBLY AND NECK FRAME. INSTALLBOLTS WITH 1/2โ WRENCH OR SOCKET.MAKE SURE THE BOLTS ARE TIGHT. THEBOLTS ARE SCREWED INTO A BRACKETINSIDE OF THE BOTTOM OF THE HANDLEASSEMBLY.
.
BOLT AND WASHER
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ASSEMBLY INSTRUCTIONS
16. GET THE RIGHT HAND UPPER COVER,ROUTE CABLE THROUGH THE WHITECLIPS, CLOSE CLIPS.
CLIP
CABLE
RIGHT UPPER COVER
17. FOR STEPPERS WITH CONTACTHEART RATE CABLE, ROUTE CABLE FROMHOLE IN HANDLE TO TOP OPENING IN THEUPPER COVER. WHEN INSTALLING THELEFT UPPER COVER AVOID PINCHING THEWIRES FROM THE HANDLE.
TOP OPENING
CONTACT HEART RATE CABLE
GROMMET ABOVE OPENING IN HANDLE
OPENING IN HANDLE
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ASSEMBLY INSTRUCTIONS
18. GET THE LEFT HAND UPPER COVER,SLIDE RUBBER GROMMET UP TO THE TOPOF THE HANDLE ASSEMBLY. POSITIONTHE RIGHT HAND UPPER COVER OVERTHE LOWER COVER AND HANDLE POST.FIT RUBBER GROMMET INTO THE RIGHTHAND UPPER COVER. POSITION THE LEFTHAND UPPER COVER OVER THE LOWERCOVER, HANDLE POST. FIT GROMMETINTO LEFT HAND COVER AND OVERLAPTHE RIGHT HAND UPPER COVER. NOTE-IFTHE COVERS DO NOT FIT THE HANDLENEEDS TO BE ROTATED 180 DEGREES.
HANDLE POST
GROMMET
RIGHT HAND UPPER COVER
LEFT HAND UPPER COVER
19. USE EIGHT PUSH RIVETS TO FASTENTHE UPPER COVERS TO EACH OTHER ONBOTH THE FRONT AND REAROVERLAPPING SEAMS. IF THE RIVETSCAN NOT BE PUSHED INTO THE MATINGHOLES USE A MALLET, OR LIGHTLY TAPWITH A HAMMER.
PUSH RIVETS
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ASSEMBLY INSTRUCTIONS
20. GET CONSOLE AND MAGAZINE RACK..POSITION BRACKET IN HOLES ANDGROOVES ON THE BACK OF THECONSOLE.
CONSOLE
HOLES IN BACK OF CONSOLE
MAGAZINE RACK
21. GET SPACER AND POSITION OVERMAGAZINE RACK ON CONSOLE.
CONSOLE
SPACER
MAGAZINE RACK
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ASSEMBLY INSTRUCTIONS
22. POSITION CONSOLE, SPACER, ANDMAGAZINE RACK ON TOP OF THE UPPERCOVERS. PLUG IN CONNECTOR FROMCABLE TO CONSOLE. BE SURE TOPOSITION THE CONNECTOR CORRECTLYWITH THE ALIGNING TAB ON THEFEMALE CONNECTOR WITH THEALIGNING SLOT ON THE MALECONNECTOR. ALIGN HOLES IN SPACER,UPPER COVERS, AND CONSOLE ..
CONSOLE
SPACER
CONNECTOR FROM CABLE
UPPER COVERS
23. FOR STEPPER WITH CONTACT HEARTRATE, CONNECT SMALL CONNECTOR TOCONSOLE IMMEDIATELY ABOVE LARGECONNECTOR. BE SURE TO POSITION THECONNECTORS CORRECTLY WITH THEALIGNING TAB ON THE FEMALECONNECTOR WITH THE ALIGNING SLOTON THE MALE CONNECTOR.
SMALL CONNECTOR
LARGE CONNECTOR
SPACER
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ASSEMBLY INSTRUCTIONS
24. USE FOUR SCREWS WITH LOCKWASHERS TO SECURE CONSOLE TO UPPERCOVERS.
SCREWS
25. GET KNIFE AND REMOVE STRETCHWRAP FROM CONSOLE AND CARTONATTACHED TO PEDAL.
CONTENTS OF CARTON FOR 4400PT:
BAG OF SPARE PLASTIC PUSH RIVETS
RIVET REMOVAL TOOL
MANUAL
POWER SUPPLY
CONTENTS OF CARTON FOR 4400CL
BAG OF SPARE PLASTIC PUSH RIVETS
RIVET REMOVAL TOOL
MANUAL
BATTERY CHARGER
CONSOLE
CARTON
SEE OWNERโS MANUAL FOR SETUP ANDOPERATING INSTRUCTIONS.
ยฉ 2001 StairMaster Health & Fitness Products, Inc. StairMaster and FreeClimber are registered trademarks or trademarks of StairMaster Health & Fitness Products, Inc. in the United States
and/or other countries. All other trademarks are trademarks of their respective companies.StairMaster is a Rutledge Capital Company
P/N 22867-A
Printed in the United States.ยฉ 2001 StairMasterยฎ Health & Fitness Products, Inc.
All rights reserved.
Corporate Headquarters12421 Willows Road N.E., Suite 100
Kirkland, WA 98034
(800) 635-2936(425) 823-1825
Fax (425) 823-9490www.stairmaster.com
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WARRANTY
This is to certify that the StairMasterยฎ FreeClimberยฎ exercise system is warrantedby StairMaster Health & Fitness Products, Inc. to be free of all defects in materialsand workmanship. This warranty does not apply to any defect caused by negligence,misuse, accident, alteration, improper maintenance, or an โact of God.โ This warrantyis non-transferable from the original owner.
If, within three years from the date of purchase, any part of the StairMasterFreeClimber exercise system should fail to operate properly (except any accessories or thebattery on the 4600 CL and the 4400 CL), contact our Customer Service Department toreport the problem. When calling, please be prepared to provide the customer servicerepresentative with the following information:
โข Your name, customer number, shipping address, and telephone numberโข The model and serial number of the inoperable machineโข The date(s) of purchase for the inoperable machine(s)โข Your billing address
This information will ensure that you are the only one ordering parts under yourwarranty protection. If warranty replacement parts are shipped to you, you may berequired to return the inoperable parts. To facilitate this process, the following policyhas been established:
โข Please call our Customer Service Department to receive a ReturnMaterial Authorization (RMA) prior to shipment.
โข StairMaster Health & Fitness Products, Inc. will incur all freightcharges for warranty parts ordered for a machine that is less than 45days old. The parts will be shipped to you via an overnight courier.*
โข You are responsible for freight charges on warranty parts formachines that are more than 45 days old. You will not be responsiblefor the return shipment of the inoperable parts.
โข Some inoperable warranty parts must be promptly returned to ourCustomer Service Department. We will pay the shipping cost for theinoperable warranty parts. Detailed instructions are included witheach warranty replacement part.
StairMaster Health & Fitness Products, Inc. neither makes, assumes, norauthorizes any representative or other person to make or assume for us, any otherwarranty whatsoever, whether expressed or implied, in connection with the sale,service, or shipment of our products. We reserve the right to make changes andimprovements in our products without incurring any obligation to similarly alter productspreviously purchased. In order to maintain your product warranty and to ensure the safeand efficient operation of your machine, only authorized replacement parts can be used.This warranty is void if parts other than those provided by StairMaster Health & FitnessProducts, Inc. are used.
* Note: Aerosol products cannot be transported via air.
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PREFACERegular use of the StairMasterยฎ FreeClimberยฎ exercise system is a safe andeffective way to develop aerobic fitness while conditioning the major musclesof the lower body. To get the best results, and to keep your machine in peakoperating condition, you should carefully read and follow the guidelinespresented in this manual.
WHAT IS IN THIS MANUAL?
The first part of this manual includes sections on safety, installation, operatinginstructions, and preventive maintenance. The second part contains detailedinformation on problem troubleshooting and repair procedures. An Appendix atthe end of the manual provides additional information for the owner.
Throughout this manual, console keypad keystrokes are enclosed in [ ].The names of the keys and special console operational modes are shown incapital letters. For example, your machine is ready to use when the consoledisplays "SELECT WORKOUT." Press [MANUAL] to start the MANUAL exerciseprogram.
WHAT IS THE STAIRMASTER FREECLIMBER EXERCISE SYSTEM?
The StairMaster FreeClimber exercise systems are vertical climbing machineswith an independent step action. The independent step action, combined withthe patented pedal geometry featured on all StairMaster steppers, provides anaerobic workout equivalent to uphill running or climbing stairs, but without thehigh-impact pounding to the joints and muscles.
There are five FreeClimber models: the 4600 PT (Personal Trainer),the 4600 CL (Cordless), the 4400 PT, the 4400 CL, and the 4200 PT. AllFreeClimbers feature the Quiet Drive transmission. The 4600 PT and the4600 CL have an adjustable tilting, full-featured Liquid Crystal Display (LCD)console. The 4400 PT and the 4400 CL have an upright, rail-less design. The4600 PT and the 4400 PT use an external power supply that is plugged into anAC wall outlet. The 4600 CL and the 4400 CL use power generated during aworkout to run the electronics. The 4600 PT and 4600 CL have contact heartrate and telemetry (Polarยฎ) heart rate monitoring. The 4400 PT and the 4400 CLfeature telemetry heart rate monitoring. The 4200 PT uses an external powersupply and the console has less feedback and fewer workout programs thanthe 4600 PT/CL and the 4400 PT/CL.
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CONTENTSSAFFETY GUIDELINES ........................................................................................ 1
INTRODUCTION ................................................................................................... 3
INSTALLATION INSTRUCTIONS........................................................................ 6
BASIC OPERATING INSTRUCTIONS ................................................................ 9General Guidelines for Safe Operation ........................................................... 9Your First Workout ......................................................................................... 10
Begin Exercising ................................................................................... 10Rest Periods .......................................................................................... 11Cool Down............................................................................................. 11
HEART RATE MONITORING ............................................................................ 13Heart Rate Input ........................................................................................... 13Locked/Non-locked Option .......................................................................... 13Error Messages ............................................................................................ 14
TELEMETRY HEART RATE (4400/4600 PT/CL ONLY) .................................. 15Using the Transmitter Belt ........................................................................... 15Maintaining the Transmitter Belt ................................................................ 16
CONTACT HEART RATE.................................................................................... 17Using Contact Heart Rate ............................................................................ 17
FREECLIMBER 4400/4600 PT/CL CONSOLE.................................................. 18Display Window ........................................................................................... 18Numeric Keypad ........................................................................................... 19Entertainment Keypad ................................................................................. 19Intensity Level Keys ..................................................................................... 19Stop Key ....................................................................................................... 19Workout Statistics ........................................................................................ 20Exercise Program Keypad ............................................................................ 21
The Quick Start Program ...................................................................... 21The Manual Program ........................................................................... 21The Fat Burner Program ....................................................................... 22The Aerobic Training Program ............................................................. 22The Speed Intervals Program .............................................................. 22The Constant Heart Rate Program ...................................................... 23
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CONTENTS
The Fitness Test Programs ................................................................... 24Understanding Submaximal Exercise Testing .................................... 24Pretest Screening ................................................................................. 26The StairMasterยฎ Submaximal Fit Test ............................................... 26The Firefighter's Stair Climb Tests ....................................................... 29
Turning on the C.P.A.T. Test ........................................................... 30Turning on the NYCFD Test ........................................................... 30
Console Codes ............................................................................................. 31Custom Codes ...................................................................................... 31
Quick Scan Programming .............................................................. 32Machine Status Codes ........................................................................ 33
Quick Scan Programming .............................................................. 34Configuration Code .............................................................................. 34
FREECLIMBER 4200 PT CONSOLE ................................................................. 35Top Window.................................................................................................. 35
Workout Setup...................................................................................... 35Timer ...................................................................................................... 36
Bottom Window ........................................................................................... 37Keypad .................................................................................................. 37
Quick Start Option ........................................................................................ 38
MAINTENANCE INSTRUCTIONS .................................................................. 39Helpful Hints ................................................................................................. 39Tool List ......................................................................................................... 39Maintenance Records ................................................................................. 39Initial Service ................................................................................................ 40Preventive Maintenance ............................................................................. 40
Cleaning ................................................................................................ 40Inspecting ............................................................................................. 40Lubrication ............................................................................................ 41Battery Charge...................................................................................... 42Battery Disposal ................................................................................... 42
TROUBLESHOOTING ........................................................................................ 44General Troubleshooting Guidelines ........................................................... 44Electrical Troubleshooting ........................................................................... 44
4600/4400 PT: ...................................................................................... 44Alternator Test ............................................................................... 45
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Diode Test ....................................................................................... 46Resistor Test ................................................................................... 46
4600/4400 CL: ...................................................................................... 46Battery Test .................................................................................... 46Alternator Test ............................................................................... 47Resistor Test ................................................................................... 47
Display Test ........................................................................................... 48Keypad Test .......................................................................................... 48Serial Port Test ...................................................................................... 49Alternator Test ...................................................................................... 49Tach Test ............................................................................................... 50Error Reporting...................................................................................... 50Contact Heart Rate Test ....................................................................... 51Telemetry Heart Rate Test .................................................................... 51
Mechanical Troubleshooting ....................................................................... 53
PARTS REMOVAL AND REPLACEMENT ....................................................... 56Covers ........................................................................................................... 56
Mid Cover ............................................................................................. 56Top Cover .............................................................................................. 56Shield (4600 PT/CL ) ............................................................................. 57Bottom Cover ........................................................................................ 57
Console ......................................................................................................... 58Console Adjustment (4600 PT/CL) .............................................................. 58Poly-V and HTD Belt ..................................................................................... 58Step Chain Retainer ..................................................................................... 59Pedal Arm Return Spring ............................................................................. 59Step Chain .................................................................................................... 60Spring Pulley ................................................................................................. 61Drive Chain ................................................................................................... 61Drive Shaft Assembly ................................................................................... 62Pedal ............................................................................................................. 64Leveling Arm ................................................................................................. 64Pedal Arm...................................................................................................... 65Pedal Pad ...................................................................................................... 65Eccentric Hub Assembly ............................................................................... 66
CONTENTS
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First Reduction Shaft Assembly .................................................................. 66Handlebar (4400 PT/CL, 4200 PT) ............................................................... 66Upper Handles (4600 PT/CL) ........................................................................ 67Side Handrails (4600 PT/CL) ........................................................................ 67Alternator ...................................................................................................... 68
GROUNDING INSTRUCTIONS ......................................................................... 69
FCC COMPLIANCE ............................................................................................. 70
APPENDICES
Canadian Doc Class B Compliance ............................................................. 70Important Phone Numbers ........................................................................... 71Battery Recycling Centers ........................................................................... 72Figures 10-27 ................................................................................................ 74
LIST OF TABLES
Table 1. Dimensions and Specifications for the StairMasterยฎ FreeClimberยฎ Exercise Systems .................................. 5
Table 2. Fitness Rating Norms (VO2max) ........................................................ 29Table 3. Recommended Preventive Maintenance Schedule .................... 43
LIST OF ILLUSTRATIONS
Figure 1: Major Parts - 4600 PT/CL ................................................................. 3Figure 2: Major Parts - 4200 PT and 4400 PT/CL ......................................... 4Figure 3: Level Adjusting End Caps ............................................................... 6Figure 4: DC Power Connector ....................................................................... 7Figure 5: Correct Exercise Postion ............................................................... 12Figure 6: Transmitter Belt ............................................................................. 16Figure 7: FreeClimber 4400/4600 PT/CL Systems Console ....................... 18Figure 8: StairMaster Fitness Protocol ........................................................ 28Figure 9: 4200 PT Console Diagram ............................................................ 35Figure 10: Grounding System ...................................................................... 69Figure 11: Parts Needing Periodic Maintenance ....................................... 74
CONTENTS
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Figure 12: Final Assembly - Left, 4600 PT ................................................... 75Figure 13: Final Assembly - Right, 4600 PT ................................................. 76Figure 14: Final Assembly - Left, 4600 CL ................................................... 77Figure 15: Final Assembly - Right, 4600 CL ................................................. 78Figure 16: Covers - 4600 PT/CL ................................................................... 79Figure 17: Pedal Arm Assembly & First Reduction Shaft Assembly
(4600/4400 PT/CL, 4200 PT) ........................................................ 80Figure 18: Drive Shaft Assembly & Eccentric Hub Assembly
(4600/4400 PT/CL, 4200 PT) ........................................................ 81Figure 19: Final Assembly - Left, 4400/4200 PT ......................................... 82Figure 20: Final Assembly - Right, 4400/4200 PT ....................................... 83Figure 21: Final Assembly - Left, 4400 CL ................................................... 84Figure 22: Final Assembly - Right, 4400 CL ................................................. 85Figure 23: Covers - 4400 PT/CL, 4200 PT ................................................... 86Figure 24: Cover Removal ............................................................................ 87Figure 25: Cover Fasteners .......................................................................... 88Figure 26: Drive Chain Tensioning .............................................................. 89Figure 27: Belt Tension ................................................................................ 90
CONTENTS
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๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ
๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ
This symbol appearing throughout this manual meansAttention! Be Alert! Your safety is involved.
The following definitions apply to the words โDangerโ and โWarningโfound throughout this manual:
๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ ๏ฟฝ ๏ฟฝ๏ฟฝUsed to call attention to IMMEDIATE hazards which, if notavoided, will result in immediate, serious personal injury or loss of life.
๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝUsed to call attention to POTENTIAL hazards that couldresult in personal injury or loss of life.
๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ
To reduce the risk of electrical shock, always unplugthe external power supply from the AC wall outletbefore cleaning, maintaining, or repairing.
To reduce the risk of burns, electric shock, or injuryto persons:
1. The external power supply should always be unplugged from the AC walloutlet before removing or installing parts. Never make adjustments orrepairs while an exercise program is in progress.
2. Close supervision is necessary whenever the machine is used by or nearchildren, invalids, or disabled persons.
3. Keep your hands away from all moving parts and keep your feet on thepedals while exercising. Do not operate the machine with the side coversremoved.
SAFETY GUIDELINES
๏ฟฝ
๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ ๏ฟฝ
๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ๏ฟฝ
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4. Use this machine only for its intended use as described in this Manual. Donot use parts, attachments, or accessories other than those provided byStairMasterยฎ Health & Fitness Products, Inc.
5. Do not use the external power supply if it has a damaged cord or plug, or ifit is not working properly, if it has been dropped or damaged, or droppedinto water. Contact our Customer Service Department at 1-800-331-3578 to arrange for the return of damaged parts.
6. Connect the external power supply to a properly grounded AC walloutlet; refer to the โGrounding Instructionsโ section. Keep all cordsaway from heated surfaces.
7. To disconnect the external power supply, remove the plug from the ACwall outlet.
8. Never drop or insert any object into any opening on the machine.
9. Do not operate where aerosol (spray) products are being used.
10. Always wear insulated gloves when handling batteries.
11. Do not crush, incinerate, or dismantle the battery. The electrolyte containssulfuric acid which can cause serious damage to eyes and skin. Shouldthis occur, flush profusely with water and seek medical attention.
12. Do not use the machine outdoors.
The safety level given by the design of this equipment can only bemaintained when the equipment is regularly examined for damage and wear.Inoperable components shall be replaced immediately or the equipment shallbe put out of use until it is repaired. Failure to follow all guidelines may com-promise the effectiveness of the exercise experience, expose yourself (andpossibly others) to injury, and reduce the longevity of the machine. Follow alltraining instructions listed in the manual and/or on the machine. Physical injurymay result from incorrect or excessive training.
SAVE THESE INSTRUCTIONS
SAFETY GUIDELINES
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Before leaving the manufacturing facility in Tulsa, Oklahoma, yourStairMasterยฎ FreeClimberยฎ exercise system was thoroughly inspected andtested to ensure proper operation. The major parts of the machine are shownin Figures 1 and 2.
Figure 1: Major Parts - 4600 PT/CL
INTRODUCTION
Pivotng Consoli! Mo~t
BottDm Cover
\
Console
Handles
/ Shield
left Hancbil
/
leftPadal
T~m~~~~==~~~ SIDE VIEW
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Figure 2: Major Parts - 4200 PT and 4400 PT/CL
INTRODUCTION
Handlebars
Mid cover
Left pedal
Top cover
Bottom cover
-odjusting end co p
Step Chain
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Throughout this Manual, all references to the left or right side and to thefront or back are made as if you were on the machine, ready to exercise. Forexample, the console is located on the front of the machine. The dimensionsand general specifications of the machines are listed in Table 1.
Table 1. Dimensions and Specifications for theStairMasterยฎ FreeClimberยฎ Exercise Systems
Physical Dimensions:
Length 44 inches (104 cm)Width at Front Leg (4400 PT/CL, 4200 PT) 22 inches (56 cm)Width at Front Leg (4600 PT/CL) 32 inches (82 cm)Height 69 inches (176 cm)Weight
4400 PT/CL, 4200 PT 126 pounds (55 kg)4600 PT/CL 155 pounds (70 kg)
Power Supply Specifications:
4600/4400/4200 PT (U.S., Canada, Japan) 120 VAC, 50/60 Hz, 2.5 Amp4600/4400/4200 PT (International) 230 VAC, 50/60 Hz, 2.5 Amp
Battery Charger Specifications:
4600/4400 CL (U.S., Canada, Japan) 120 VAC, 50/60 Hz, 1 Amp4600/4400 CL (International) 230 VAC, 50/60 Hz, 1 Amp
Internal Battery6 volt, 1 Ah Lead-Acid battery
INTRODUCTION
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Assemble your machine before use. Machines shipped outside the UnitedStates need to be uncrated before they can be assembled; refer to theโUncrating Instructionsโ included with your machine for the details.
1. Remove all shipping material from your machine once it is in place.
2. Make sure the machine is level before you use it for the first time. Thefour rubber end caps (see Figure 3) are designed to compensate foruneven floors. Each face of the caps is a different thickness. Twist thecaps to stabilize the machine.
Figure 3: Level Adjusting End Caps
3. Open the box you removed from the pedals. The box contains eitheran external power supply (4600/4400/4200 PT only) or a wall-packbattery charger (4600/4400 CL only). The battery charger is onlyused to recharge a low battery.
INSTALLATION INSTRUCTIONS
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4. If you have a 4600/4400 CL, skip to step 9. If you have a 4600/4400/4200 PT, connect the DC cable of the power supply to the connectornear the bottom of the left side cover (see Figure 4).
Figure 4: DC Power Connector
5. Place the power supply on the floor near an AC wall outlet. To reducethe hazard of electrical shock, place the power supply in a locationaway from the machine and away from exposure to perspiration. Youshould not place your power supply on a carpet because it may overheat.
INSTALLATION INSTRUCTIONS
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6. Check to be sure that the input AC power rating marked on the powersupply matches the available power. If it does not, obtain the match-ing power supply from StairMasterยฎ Health & Fitness Products, Inc.before proceeding any further.
7. Connect the AC power cord to the AC wall outlet. Refer to theโGrounding Instructionsโ section if the AC wall outlet does notaccept athree-prong plug.
8. Watch the console. The 4600/4400 PT should display a softwarerevision code and then show โSELECT WORKOUT.โ The 4200 PTconsole should run through a self test and then display a moving linein the upper LCD window. If the console does not, unplug the powersupply and then plug it back in. If the console still does not power upcorrectly, contact our Customer Service Department. Refer to theAppendix for the appropriate phone number.
9. If you have a 4600/4400 CL, step on the pedals to check for properoperation. Once you step on the pedals, the console should display asoftware revision code and then show โSELECT WORKOUT.โ If itdoes not, connect the battery charger to the connector on the lowerleft side. If the console still does not power up contact our CustomerService Department. Refer to the Appendix for the appropriate phonenumber.
10. The display โSELECT WORKOUTโ tells you the machine is ready touse. The 4600/4400 PT/CL console displays this message and the4200 PT displays a moving line in the upper LCD window when theconsole is ready to use.
INSTALLATION INSTRUCTIONS
TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TOPREVENT SEVERE DAMAGE TO THE MACHINE, USE ONLY THE POWER SUPPLY
APPROVED FOR USE WITH THIS EQUIPMENT. IN ADDITION,YOUR MACHINE MUST BE PROPERLY GROUNDED.
๏ฟฝ WARNING
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GENERAL GUIDELINES FOR SAFE OPERATION
1. Obtain a complete physical examination from your medical doctor andenlist a health/fitness professionalโs aid in developing an exerciseprogram suitable for your current health status.
2. When working out for the first time, use the MANUAL exerciseprogram at the lower speeds until you feel comfortable and capableof faster speeds.
3. The speed and duration of your exercise program should always besubject to how you feel. Never permit peer pressure to override yourpersonal judgment while exercising.
4. Overweight or severely deconditioned individuals should be particu-larly cautious when using the machine for the first time. Even thoughsuch individuals may not have histories of serious physical problems,they may perceive the exercise to be far less intense than it really is,resulting in the possibility of overexertion or injury.
5. Although all equipment manufactured by StairMasterยฎ Health &Fitness Products, Inc. has been thoroughly inspected by the manufac-turing facility prior to shipment, proper installation and regular mainte-nance are required to ensure safety. Maintenance is the sole respon-sibility of the owner.
BASIC OPERATING INSTRUCTIONS
๏ฟฝ WARNING
THESE GUIDELINES ARE DIRECTED TO YOU, AS THE OWNER OF THE MACHINE.YOU SHOULD INSIST THAT ALL USERS FOLLOW THE SAME GUIDELINES.
YOU SHOULD MAKE THIS MANUAL AVAILABLE TO ALL USERS.
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YOUR FIRST WORKOUT ON THE STAIRMASTERยฎ FREECLIMBERยฎ
EXERCISE SYSTEM
1. Warm up with light calisthenics and easy stretching exercises for atleast five minutes before beginning your exercise program.
2. Hold onto the handlebars and step up onto the pedals. Stand upstraight. The pedals will sink slowly toward the floor.
3. Select the MANUAL exercise program so you can control the pace ofyour first workout and get used to the exercise motion. Press[MANUAL] and then press [ENTER]. The console will return tothe start screen if you do not press [ENTER] within 60 seconds.
4. The console will prompt you to enter your body weight. Enter yourweight in pounds (or kilograms if the console is set up for metricunits). Correct entry errors by pressing [CLEAR] before you press[ENTER].
5. The console will prompt you to enter your intensity level. Enter yourdesired intensity level. Correct entry errors by pressing [CLEAR] beforeyou press [ENTER].
6. The console will prompt you to enter the workout time in one minuteincrements between 5 and 99 minutes. Press [1], [0], [ENTER] toexercise for ten minutes. If you do not start exercising within 60seconds, the console will return to the start screen.
Begin Exercising
7. Take deep, comfortable steps. Do not let the pedals touch the floor orcontact the upper stop. When you begin to exercise, the MANUAL
BASIC OPERATING INSTRUCTIONS
๏ฟฝ WARNING
IF AT ANY TIME DURING YOUR WORKOUT YOU FEEL CHEST PAIN,EXPERIENCE SEVERE MUSCULAR DISCOMFORT, FEEL FAINT, OR ARE SHORT OFBREATH, STOP EXERCISING IMMEDIATELY. IF THE CONDITION PERSISTS, YOU
SHOULD CONSULT YOUR MEDICAL DOCTOR IMMEDIATELY.
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program starts at level three.
8. As you become comfortable with exercise motion, press[LEVEL: โง] and [LEVEL: โจ] to adjust your climbing speed.
9. Relax and stand up straight while exercising. Use thehandlebars for balance (see Figure 5).
10. Select an intensity level that allows you to stay in the middleof the pedal range of motion. Faster is not always better.Exercise at a level that is consistent with your fitness level.
Rest Periods
11. You can stop and rest as many times as necessary for up to oneminute for each rest period during all programs. To stop, either press[STOP] or step off the machine.The 4400/4600 PT console returns tothe start screen if you rest longer than the allotted rest period. The4400/4600 CL console will shut off if you rest longer than the allottedrest period. Follow the onscreen prompt to continue your work outafter a rest period.
Cool Down
12. When you are finished with your workout, the machine will slowdown and the message โGOAL ATTAINEDโ will be displayed. You cancool down on the machine by continuing to step. The console timerwill continue to count up from the selected time, and the intensitylevel will default to level 3. If there is a time limit set on the console,the timer will last only until the maximum time has been met. Forexample, if the time limit was set for 30 minutes and you worked outfor 25 minutes, the cool down period would last for 5 minutes, or untilyou stepped off the machine.
13. You can also cool down by getting off the machine walking orstretching for at least five minutes. Lift one foot slowly until the pedalarm contacts the upper stop. Place that foot on the floor. Repeat forthe other foot. Do not let the pedals slam into the upper stops, sincethis may cause unnecessary wear and tear.
BASIC OPERATING INSTRUCTIONS
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Head - Keep your chin parallelto the floor. Avoid staring at yourfeet or the computer console. Thisposture will also enhance yourbreathing.
Back - Although the wholebody is in a slightly forwardslant, keep your back straightand avoid bending at the waist.
Hips/Torso - Keep your hipsdirectly under you with thebuttocks slightly contracted.Avoid letting your hips rockfrom side to side with each step.
Legs - Use a full, pain-freerange of motion with eachstep, straightening your legsas far as possible withoutcausing discomfort or lettingyour knees lock out.
Feet - Place 3/4 of each foot on the ped-als, heels slightly off the edge with yourtoes facing forward.
Chest/Shoulders - Keep yourshoulders square and centeredover your hips with your chestlifted.
Hands - Rest yourhands lightly on theside rails or fronthandlebars.Excessive leaning onthe side rails can re-duce calorie burn byup to 20%.
Elbows - Keep both elbowsslightly bent. If you have goodbalance and want to burn morecalories, you can pump your armsback and forth as if you wererunning.
Knees - Keep your kneesaligned with your toes.Avoid training with yourknees too far past yourtoes and keep your feetpointing forward. Do nothyperextend your knees.
Figure 5: Correct Exercise Position
BASIC OPERATING INSTRUCTIONS
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HEART RATE MONITORING
HEART RATE INPUT
Contact heart rate and telemetry (e.g., Polarยฎ) heart rate signal detection isavailable. There is no default priority of heart rate input. If a telemetry signalis detected first, contact heart rate signals are inhibited from being detectedthroughout the rest of the workout session and vice-versa. There is also ashort โlock outโ period at the beginning of each workout session during whichthe console first detects a signal and then validates the signal type. Theduration of this shorter, initial โlock outโ period differs between telemetry andcontact heart rate.
โข Telemetry heart rate - after the initial belt signal is detected, theconsole will enter a validation phase in which four good heartbeat signals within four seconds are required beforelocking on telemetry heart rate signals for the duration of theworkout session. During the validation phase the console will notrecognize contact heart rate signals.
โข Contact heart rate - after the initial contact sensor signal isdetected, the console will enter a validation phase requiring agood heart beat signal within 10 to 15 seconds, or until thesystem acquires a valid signal. During the validation phase, theconsole will not recognize telemetry heart rate signals. Theconsole will display a beating double heart icon that has theinner heart colored in while searching for a valid signal.
Locked/Non-locked Option
When the โnot lockedโ option is selected the heart rate source signal is notfixed during the exercise (if the signal is lost, either input will be valid). If theโlockedโ option is selected, then the heart rate source signal is locked on thefirst detected signal during the workout. To set a heart rate signal input, or toturn off the heart rate option all together, perform the following steps:
1. On the console keypad, press [LEVEL: โง] , [3], [2]. At this point thescreen will display โHR INPUTS.โ Press [ENTER] to select thisoption.
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HEART RATE MONITORING
2. There are four options to handle heart rate input signals.Press the [SELECT] key to scroll through the options until youfind the one option that suits your needs. Press the [ENTER]key to select that option.
โ BOTH HR ON โ - allows either telemetry or contact heart ratesignals to be detected. Once the console has detected a validinput signal it will lock out the opposite type of signal for theduration of the workout session. For example, if you start outusing contact heart rate then you are limited to using only contactheart rate during your workout session, even if the signal is lostwhile performing the workout, and vice-versa.โ BOTH NOT LOCKEDโ - allows either telemetry or contactheart rate signals to be detected. Does not lock out a particularinput signal for the entire workout. This option will detect eitherinput signal during a workout session, but only one at a time, andonly until the other signal terminates.โ TELEMETRY ONLY โ - locks out contact heart rate signalsand will only detect telemetry signals.โ HAND ONLY โ - locks out telemetry signals and will only detectcontact heart rate signals.โ BOTH HR OFF โ - turns off the ability to detect any signal at all.Used in rare situations where there is excessive interference withthe heart rate signals. *This option disables the Constant HRprogram and the Fitness Test program.
Error Messages
Text line messages are only seen in the Constant Heart Rate and Fitness Testprograms due to the design of the program that necessitates a valid heart ratesignal during the program. For these programs, ensure that neither the โBOTHHR OFFโ or the โHAND ONLYโ option is set as a default option.
โCHECK HR BELTโ - The heart rate signal has been missing for the last 30seconds in telemetry signal detection.โHR BELT NEEDEDโ - No telemetry belt signal has been sensed during theinitial setup time.
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โHOLD HR SENSORSโ - In contact heart rate signal situations this messagewill come every 30 seconds to prompt the user to hold the sensors.โHR MODE DISABLEDโ - No heart rate signal is allowed due to the set upoption that was chosen. Heart rate monitoring is not possible.
TELEMETRY HEART RATE (4600/4400 PT/CL ONLY)
The StairMasterยฎ FreeClimberยฎ 4600/4400 PT/CL features telemetry (Polarยฎ)heart rate monitoring. The system consists of the receiver, located on the step-per, and a transmitter belt (purchased separately) worn across your chest. Themonitoring function is activated as soon as you strap on the chest belt andstep within range of the receiver in the machine. Two electrodes on the under-side of the chest belt sense the heart rate signal and send it to the receiver.The heart symbol on the console pulses to indicate that the console is receiv-ing a valid signal. A microprocessor in the console calculates the heart rateand displays it, in beats per minute, on the console.
Using the Transmitter Belt
Before you put the transmitter belt on, wet the two electrode patches(the grooved rectangles on the reverse side of the belt). Secure the transmitterbelt as high under the pectoral muscles (chest) as is comfortable. The transmit-ter belt should fit snugly and comfortably, and allow normal breathing. Whenthe console detects a heart rate signal, heart rate is shown in the display auto-matically. Your heart rate in beats per minute and a pulsing heart icon are dis-played on the console.
After the initial belt signal is detected, the console will enter a valida-tion phase in which four good heart beat signals lasting four seconds arerequired before locking on telemetry heart rate signals for the duration of theworkout session. During the validation phase the console will not recognize
TELEMETRY HEART RATE
PACEMAKER USERS SHOULD NOT USE THE POLARTRANMITTER BEFORE CONSULTING THEIR DOCTOR.
๏ฟฝ WARNING
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contact heart rate signals. If you do not see a heart rate on the console, try oneof the following:
โข Move closer to the console.โข Tighten the elastic part of the chest belt.โข Adjust the belt higher or lower on your chest.โข Remoisten the electrodes.โข Test your chest strap with a machine that you know is working, or
with a heart rate watch that you know is working.โข If possible, replace or exchange your console with a console
(from the same type of machine) that you know is working andretest the machine.
โข Verify that the console software has been set up properly forheart rate detection (see pg. 13-14).
Figure 6: Transmitter Belt
Maintaining the Transmitter Belt
Clean the chest belt regularly with mild soap and water, then dry thoroughly -residual sweat and moisture keep the transmitter active and drain the batteryin the transmitter. Do not use abrasives or chemicals such as steel wool oralcohol for cleaning, as they can damage the electrodes permanently. You canorder replacement belts from StairMaster, Polar Electro, Inc., or your localfitness store:
StairMaster 800-331-3578 P/N 64000Polar Electro, Inc. 800-227-1314
TELEMETRY HEART RATE
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CONTACT HEART RATE
The StairMasterยฎ FreeClimberยฎ 4600 PT/CL features a digitized contact heartrate monitoring system. Through the use of stainless steel sensors built intothe upper handles and sophisticated software, heart rate can be checked atany time during a workout. The heart rate is displayed on the console. Contactheart monitoring is standard on the 4600 PT/CL and optional on the 4400PT/CL.
The contact heart rate system is very accurate (within 3% of themedical standard), but its ability to detect a heart rate signal is influenced byseveral factors. Movement of the muscles of the upper body produces anelectrical signal (muscle artifact) that will interfere with the detection of theheart rate signal by the sensors. Movement of the hands while they are incontact with the sensors also produces interference. Calluses and hand lotionact as an insulating layer to reduce the signal strength. Also, the EKG signalgenerated by some individuals is not strong enough to be detected by thesensors. Typically, these individuals account for 5 - 7% of the population.These individuals should opt for the Polarยฎ chest strap method of heart ratemonitoring. Most people (between 93 โ 95%) will not have a problem with thesystem provided interference from movement is minimal.
Using Contact Heart Rate
Contact heart rate input signals are acquired only during contactbetween your hands and the stainless steel sensors on the handrails. To usethe contact heart rate feature, place your hands around the handles so thatyour hands touch both the top and the bottom of the sensors. After the initialcontact heart rate signal is detected, the console will enter a validation phaserequiring a good heart beat signal within 10 to 15 seconds, or until the systemacquires a valid signal. During the validation phase the console will not recog-nize telemetry heart rate signals. The console will display a beating doubleheart icon that has the inner heart colored in while searching for a valid signal.If, during exercise, the heart rate displayed is erratic, it may be helpful toremove your hands from the handles, wipe them and place them back on thehandles. In all programs, the heart rate is shown automatically in the displaywindow the first time the sensors are touched.
CONTACT HEART RATE
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The StairMasterยฎ FreeClimber 4400/4600 PT/CL systems console is dividedinto seven sections: the display window, the workout options, the numeric key-pad, the entertainment keypad, the workout statistics, the stop key, and theintensity level keys (see Figure 7).
Figure 7: FreeClimber 4400/4600 PT/CL Systems Console
DISPLAY WINDOW
โข Time - The selected workout time is displayed inthe upper left section of the display window. Oncethe time is entered, the timer will count down, in min-utes and seconds, until the workout is finished orstopped. If [0] is entered in the MANUAL or CON-STANT HEART RATE program, the timer will count up.
โข Calories - The real-time amount of calories burned is continually updatedand displayed in the upper right section of the display window.โข Interval Timer - The interval timer is displayed below the Time. The intervaltimer counts down time left within each interval.โข Heart Rate - Current heart rate is displayed below the Calories, next to theheart icon.โข Workout Option Profile - A profile of the selected exercise program ap-pears in the lower section of the display window during a workout. The tallerthe column, the higher the intensity (watts) for that interval. The flashing col-umn shows your current interval. The flashing column moves from left to rightacross the display as you complete each interval.
FREECLIMBER 4400/4600 PT/CL CONSOLE
Display Window
EntertainmentKeypad
NumericKeypadWorkout Options
Workout Statistics Stop Intensity Level
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NUMERIC KEYPAD
The numeric keypad is located on the right side of the con-sole. Before the exercise program begins, the numbers areused to enter data in response to the console prompts.โข Enter - Confirms workout selections and stores the informa-tion used by the console to calculate workout statistics.โข Clear - Erases information from the console memory ifpressed before [ENTER].
ENTERTAINMENT KEYPAD
The FreeClimber comes equipped to facilitate the use of com-mercial entertainment systems. Using any of these keys willsend an output signal through the Communication Specifica-tion for Fitness Equipment (C.S.A.F.E.) port to a connectedC.S.A.F.E. or compatible system. If a system is not connected,pressing these keys will have no effect.
โข Volume Up/Down - Increases or decreases the volume level of the audiosource.โข Mute - Removes the audio sound from the headphones.โข Channel Up/Down - Changes the channel of the commercial entertainmentsystem.
INTENSITY LEVEL KEYS
The exercise intensity level may be changed at any time dur-ing a workout. Pressing the [ โจ ] key decreases the intensityand pressing the [ โง ] key increases the intensity.
STOP KEYPress the [STOP] key any time you want to pause the exerciseprogram for up to one minute. Press [STOP] a second time, or[1], and The console will return to the "SELECT WORKOUT"Prompt.
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WORKOUT STATISTICS
During the exercise program, the Stats keys are used to track workout statis-tics which are then shown in the display window. Pressing the [SELECT] keyturns off the scanning feature and shows the statistic of choice in the displaywindow. Continue to press the [SELECT] key until you reach the desiredstatistic. Pressing the [SCAN] key will prompt the console to cycle through thefollowing statistics:
โข Distance - Provides a cumulative total of the equivalent distance (in milesor kilometers), you would have traveled while riding a bicycle outdoors at thesame relative intensity.โข Calories/Hour - Provides a running total of the number of calories burnedduring a workout.โข Rate - Displays the current steps per minute.โข Floors - Displays the equivalent number of floors climbed with an 8-inchstep. There are 16 steps per floor, and 48 floors per mile.โข Level - Shows the current intensity level between 1 (the easiest) and 20 (thehardest).โข Watts - Displays the exercise intensity in watts (746 watts = 1 horsepower).โข METs - Gives you the relative energy cost of exercise. MET stands for mul-tiples of the resting metabolic rate. While you are sitting quietly, your bodyconsumes oxygen at the rate of about 3.5 milliliters per kilogram of body massper minute. When you exercise, your body needs more oxygen in order to func-tion. For example, exercising at 10 METs requires ten times the resting rate ofoxygen consumption, or about 35 milliliters per kilogram per minute. During aworkout, this key shows the current MET level. During the workout summary,the average MET level is displayed.โข Target Heart Rate - Available only during the Constant Heart Rate pro-gram. Shows the selected target heart rate.
At the completion of a workout, the statistic averages are calculatedbased on the accumulation of data during the workout program, and not notincluding the cool down period.
FREECLIMBER 4400/4600 PT/CL CONSOLE
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EXERCISE PROGRAM KEYPAD
The exercise keypad is located below the display and to the left of the functionkeypad. While the console is in the โSELECT WORKOUTโ mode, press one ofthe exercise program keys to preview the desired workout. There are sixworkout programs with the following standard defaults (pressing [ENTER]without inputting data first will prompt the console to enter these values):
โข Weight - 175 lbs.โข Intensity Level - 3โข Workout Time - The default time in the programmed workouts
and Quick Start is 20 minutes. The Manual and Constant HeartRate programs do not have a specified default time. In theseprograms, the console timer will count up to the maximum time of99 minutes, and then return to 0.
โข Age (Constant Heart Rate program only) - 40 years
Once you have selected a program, the prompts are:
โข โENTER BODY WEIGHTโ - type in your body weight inpounds (or kilograms if your console is set to metric units).
โข โENTER LEVEL 1 - 20โ - select your intensity level withlevel 1 being the easiest and level 20 the hardest.
โข โENTER TIME 5 - 99โ - select the workout duration in oneminute increments from 5 to 99. Press 0 in the MANUAL andCONSTANT HEART RATE program to workout for an unspecifiedamount of time.
The Quick Start Program
Provides an immediate start, without having to enter any user information. Thisprogram uses the standard default settings for derivation of calories burned.
The Manual Program
After pressing the [MANUAL] key, enter user and workout information. Beginexercising at the selected level. If desired, adjust the workout manually byusing the intensity level arrow keys. The profile in the display window isdivided into 15 equal intervals within the workout time. The profile is based
FREECLIMBER 4400/4600 PT/CL CONSOLE
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on the selected intensity level, with 2 levels equating to one vertical bar.
The Fat Burner Program
The Fat Burner program is a 60-interval workout designed for people juststarting a weight control program. The relative intensity level is indicated onthe profile and any changes in the intensity level will continue for theremainder of the program.
The Aerobic Training Program
The Aerobic Training program is a 60-interval workout designed to increaseaerobic capacity. The relative intensity level is indicated on the profile and anychanges in the intensity level will not change the look of the remaining profile.
The Speed Intervals Program
The Speed Intervals program is a workout with 8-rest intervals and 7-exerciseintervals that alternate speed/intensity level changes. You can change theREST interval speed/level and the EXERCISE interval speed/level indepen-dently, using the level keys. For example, if you decrease the intensity levelduring a rest interval then subsequent rest intervals will be the same. How-ever, the EXERCISE interval remains at the same intensity level you startedwith. To change the intensity level of the EXERCISE interval, you must change
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the intensity level during an EXERCISE interval. The intensity level shown dur-ing an EXERCISE interval is indicative of your current speed. However, the cur-rent speed during a REST interval is equal to a scaled percentage of the dis-played intensity level. Note that the program profile does not change at anytime during the workout session.
The Constant Heart Rate Program
The Constant Heart Rate program maintains a chosen target heart rate byautomatically varying the climbing speed during each workout. The defaulttarget heart rate is equal to 70% of your maximum heart rate which is calcu-lated by the following equation: 220 - (Age) x .70. Choose a different targetheart rate (between 80 and 180 beats per minute) at any time during the work-out by using the numeric keypad to enter the new target heart rate, followedby the [ENTER] key. The following messages may be shown during a workout:
โข โCHECK HR BELTโ - The heart rate signal has been missing forthe last 30 seconds in telemetry signal detection.
โข โHR BELT NEEDEDโ - No telemetry belt signal has been sensedduring the initial setup time.
โข โHOLD HR SENSORSโ - In contact heart rate signal situationsthis message will come every 30 seconds to prompt the user tohold the sensors.
โข โHR MODE DISABLEDโ - No heart rate signal is allowed due tothe set up option that was chosen. Heart rate monitoring is notpossible.
FREECLIMBER 4400/4600 PT/CL CONSOLE
Rest Interval Exercise Interval
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FREECLIMBER 4400/4600 PT/CL CONSOLE
THE FITNESS TEST PROGRAMS
Understanding Submaximal Exercise Testing
Before using the StairMasterยฎ FreeClimberยฎ for submaximal exercise testing,it should be noted that all submaximal fitness tests make several assumptions:
โข That a steady-state heart rate is obtained for each exerciseworkload.
โข That a linear relationship exists between heart rate, oxygenuptake and workload.
โข That the maximal heart rate for a given age is uniform.โข That the mechanical efficiency of the physical activity performed
(i.e., oxygen uptake at a given workload) is the same foreveryone.
It should be kept in mind that any one or all of the above mentionedassumptions may not be met during a submaximal exercise test. If for anyreason one of the assumptions is not met, then errors in predicting VO2 max willoccur.
Unfortunately, it is often quite difficult to meet all of the requirementsfor the four listed assumptions. For example, exercising at a given workload foronly a few minutes can involve an insufficient amount of time for many indi-viduals to achieve a true steady-state. To ensure that a steady-state has beenachieved, the heart rate should be measured after two minutes of exercise ata given workload and again after the third minute of exercise at that workload.These two heart rates should then be compared. If a difference of more thanfive beats per minute between the two is found, the subject should continue toexercise at one-minute intervals at the same workload until two successiveheart rates differ by less than five beats per minute.
It is also important that the submaximal heart rates obtained bebetween 115 and 150 beats per minute, because it is within this heart raterange that a linear relationship tends to exist between heart rate and oxygenuptake or workload for most adults. When the heart rate is less than 115,many external factors (e.g., talking, laughing, apprehension, etc.) can greatlyinfluence heart rate. Once the heart rate reaches a level between 115 and
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FREECLIMBER 4400/4600 PT/CL CONSOLE
150, external factors no longer influence heart rate, and a linear relationshipexists. As the heart rate rises above 150, the heart-rate/oxygen uptake rela-tionship becomes curvilinear.
The third assumption involves maximal heart rate. Maximal heart rateis the greatest heart rate that can be measured when an individual is exercis-ing to the point of volitional fatigue (i.e., exhaustion) during a graded exercisetest. Several equations have been developed to estimate the average maximalheart rate for humans:
โข Maximal heart rate = 220 minus age (low estimate)โข Maximal heart rate = 210 minus [0.5 x age] (high estimate)โข Maximal heart rate = 226 minus age (estimate for older
individuals)
Maximal heart rate can, however, vary greatly among differentindividuals of the same age. One standard deviation is ยฑ12 bpm, which meansthat two-thirds of the population varies an average of plus or minus 12 heartbeats from the average given by a prediction equation. If an individualโs age-predicted maximal heart rate is higher than that personโs true maximal heartrate, then his/her estimated VO2 max will be an overestimation of the correct oractual value.
The final assumption addresses the issue of mechanical efficiency.Oxygen uptake at any given work rate can vary by approximately 15%between different individuals. Therefore, individuals vary in the amount ofoxygen they require to perform a certain exercise workload. Some individualsare more efficient at performing a given task than others. As a result, the aver-age oxygen consumption associated with a given workload may vary signifi-cantly from one person to another. Thus, VO2 max predicted by submaximal exer-cise tests tends to be overestimated for those who are mechanically efficientand underestimated for those who are inefficient.
The point to remember is that submaximal exercise testing, thoughnot as precise as maximal exercise testing, is not without advantages. Forexample, the results of such testing can provide a fairly accurate reflection ofan individualโs fitness status without the cost, risk, effort (on the part of thesubject) and time involved in max testing. If an individual is given repeated
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submaximal exercise tests and that personโs heart rate response to a fixedworkload is found to decrease over time, it is reasonably safe to conclude thatthe individual has made improvements in aerobic (cardiorespiratory) fitness,irrespective of the accuracy of the VO2 max prediction.
Pretest Screening
Prior to any exercise test (maximal or submaximal), participants shouldcomplete a brief health/medical questionnaire, have their resting bloodpressure and heart rate measured, and provide an informed consent form.The Physical Activity Readiness Questionnaire (PAR-Q) is an example of a validhealth/medical questionnaire for screening individuals prior to submaximalexercise testing. Canadian health and fitness practitioners have extensively(and quite successfully) used the PAR-Q to determine whether individualsshould be given an exercise test. A โyesโ answer to any of the following sevenquestions taken from the PAR-Q would disqualify a participant from taking partin an exercise test until appropriate medical clearance was obtained.
PHYSICAL ACTIVITY READINESS QUESTIONNAIRE (PAR-Q)
1. Has your doctor ever said you have a heart condition and recom-mended only medically supervised physical activity?
2. Do you have chest pain brought on by physical activity?3. Have you developed chest pain within the past month?4. Do you tend to lose consciousness or fall over as a result of dizziness?5. Do you have a bone or joint problem that could be aggravated by the
proposed physical activity?6. Has a doctor ever recommended medication for your blood pressure
or a heart condition?7. Are you aware, through your own experience or a doctorโs advice, of
any other physical reason against your exercising without medicalsupervision?
The StairMaster Submaximal Fit Test
The StairMaster branching protocol is a series of 3-minute stages ofcontinuous exercise at increasing intensity. The first stage is a warmup atapproximately 4 METs. The intensity of the remaining stages is based on theheart rate response to the warmup. The test is designed to raise the steady-
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state heart rate of the subject to 110 to 150 beats/min for two consecutivestages. It is important to remember that two consecutive heart rate measure-ments must be obtained in the 110 to 150 beats/min range to predict VO2max.The test typically lasts from 9 to 15 minutes.
In the StairMaster protocol, each work rate is performed for 3minutes, with heart rates recorded during the final 4 seconds of the 2nd and 3rd
minutes of each stage. If the heart rates are within 5 beats/min, then theheart rate during the last minute is plotted against the work rate, and the pro-gram advances to the next 3-minute stage. The program continues for 2 to 4stages until 2 steady state heart rates between 110 to 150 beats/min are ob-tained in 2 consecutive stages. The line generated from the plotted points isthen extended to the age-predicted maximal heart rate. A corresponding maxi-mal work rate and VO2max can then be calculated.
At the end of the 3rd minute of each stage, if the heart rates at the endof the 2nd and 3rd minute are not within 5 beats/min of each other, then thatwork rate is maintained for an additional minute. At the end of the 4th minute,the heart rate is compared to the heart rate at the end of the 3rd minute. If theheart rates are within 5 beats/min, then the heart rate during the 4th minute isplotted against the work rate. If the heart rate at the end of the 3rd and 4th
minute are not within 5 beats/min, then the work rate is maintained for onemore additional minute. If the heart rate at the end of the 4th and 5th minutesare within 5 beats/min, then the heart rate at the end of the 5th minute is plot-ted against the work rate. If the heart rate at the end of the 4th and 5th minutesare not within 5 beats/min, then the test failed.
Once 2 consecutive heart rate measurements are obtained in the 110to 150 beats/min range, then the test ends successfully and the results aredisplayed. The estimated maximum aerobic capacity is shown in ml/kg/minand METs. Next, the results are compared to normative values for others ofthe same age range and gender (see Table 2). Results are stored in the con-sole until the next person starts an exercise program.
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Figure 8: StairMasterยฎ Fitness Protocol
First W ork Level4 M E T s
If 10 0 < = H R < = 12 0If H R < 10 0 If H R > 12 0
Second W ork Level7 M E T s
Second W ork Level6 M E T s
Second W ork Level5 M E T s
Third W ork Level9 M E T s
Fourth W ork Level1 1 M E T s
Third W ork Level8 M E T s
Fourth W ork Level1 0 M E T s
FIT TEST PROTOCOLStairMaster CV Products
Test Com plete- D isp lay R esu lts -
I f H R s > 1 15
If H R s > 1 15If H R s > 1 15
Y
YY
T e s t fa ils if 2 s tag e s o fa t lea s t 1 15 bp m a re n o t
o b ta in e d
FREECLIMBER 4400/4600 PT/CL CONSOLE
Page 29
Table 2. Fitness Rating Norms (VO2max)
MEN
Age High Good Average Fair Low 20 โ 29 >51 51 โ 47 47 โ 43 42 โ 40 <39 30 โ 39 >50 50 โ 45 45 โ 41 41 โ 37 <37 40 โ 49 >48 48 โ 42 42 โ 38 38 โ 35 <35 50 โ 59 >45 45 โ 39 38 โ 35 35 โ 32 <32 60+ >43 42 โ 35 35 โ 32 32 โ 29 <29
WOMEN
Age High Good Average Fair Low 20 โ 29 >44 44 โ 38 38 โ 35 35 โ 32 <32 30 โ 39 >41 41 โ 37 37 โ 34 34 โ 31 <30 40 โ 49 >40 39 โ 34 34 โ 31 31 โ 28 <28 50 โ 59 >35 35 โ 31 31 โ 28 28 โ 26 <25 60+ >35 35 โ 39 29 โ 26 26 โ 24 <24
The Firefighterโs Stair Climb Tests
The StairMasterยฎ Stepmillยฎ is routinely used to assess the aerobic fitnesslevels of fire fighters in full protective gear carrying heavy equipment. TheCandidateโs Physical Ability Test (CPAT), approved by the InternationalAssociation of Fire Fighters (IAFF) and reviewed by the U.S. Justice Depart-ment, requires each candidate to step on the Stepmill at a predeterminedstepping pace for a specific period of time. There are two fire fighter specificStair Climb Test programs. The first test is the CPAT Stair Climb Test. Thesecond test is a modified version of the CPAT test that is used by the New YorkCity Fire Department (NYCFD). Both tests can now be simulated on theStairMaster FreeClimber machines.
โข CPAT Stair Climb Test โ (Fit Test #2) The first phase is a warmupinterval at intensity of 56 steps/min and lasts 20 seconds. Atthe end of the first interval the time counter will reset to zero.The second phase continues through nine 20 second
FREECLIMBER 4600/4400 PT/CL CONSOLE
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intervals at an intensity of 68 steps/min. The CPAT Stair ClimbTest has a total of 10 intervals and lasts for 3 minutes, 20seconds (including warmup).
Turning on the CPAT Stair Climb Test
1. Press [โง ], [9], [1], [ENTER], on the console keypad. Make sure topress in the middle of each key and be aware that the corre-sponding numbers will not show in the console display.
2. The console will prompt you to โBEGIN FIT TEST.โ The testcan be stopped at any time by pressing [STOP].
โข NYCFD Stair Climb Test โ (Fit Test #3) The first phase is a warm-up interval at an intensity of 56 steps/min and lasts 60 seconds,followed by a 60 second rest period (no stepping). At the endof the rest period the time counter will reset to zero. The secondphase is at an intensity of 68 steps/min and lasts for 5 minutes,12 seconds.
Turning on the NYCFD Stair Climb Test
1. Press [โง ], [9], [2], [ENTER], on the console keypad. Make sure topress in the middle of each key and be aware that the corre-sponding numbers will not show in the console display.
2. The console will prompt you to โBEGIN FIT TEST.โ The testcan be stopped at any time by pressing [STOP].
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CONSOLE CODES
There are three groups of console codes which are differentiated according tofunction. The first group of codes are customization codes and are used to setdefaults such as units, language, heart rate input type, etc. The second groupof codes are machine status codes and are used to track hours and other gen-eral usage patterns for maintenance purposes. The third group of codes arediagnostic codes and are used for troubleshooting. The following key actionsare valid in each group of console codes:
โข Pressing [LEVEL โง ], [ 1st # ], [ENTER] displays what group of codes isbeing accessed.
โข Pressing [SELECT] or [LEVEL โง ] at that point allows you to view allpossible selections. Once in this mode pressing [LEVEL โจ ] backs upthrough the selections; pressing [ENTER] then selects that item. Ifanother test level is available at this point, the [SELECT] / [ENTER]process is repeated.
โข Pressing [โง ] [1st #, or 2nd #], [ENTER ] selects that item directly.โข Pressing [CLEAR] exits any of the special access modes.
Custom Codes
[ ^ ] [ 3 ] [ 0 ] change workout time limit between 5 to 99 minutes[ ^ ] [ 3] [ 1 ] change units (MPH or KMH)[ ^ ] [ 3 ] [ 2 ] choose type of heart rate input and priority (telemetry
or contact)[ ^ ] [ 3 ] [ 3 ] - N/A -[ ^ ] [ 3 ] [ 4 ] choose console language[ ^ ] [ 3 ] [ 5 ] change contrast on console[ ^ ] [ 3 ] [ 6 ] - N/A -[ ^ ] [ 3 ] [ 7 ] - N/A -[ ^ ] [ 3 ] [ 8 ] - N/A -[ ^ ] [ 3 ] [ 9 ] reset to factory defaults
1. Change the workout time by pressing [LEVEL: ^], [3 , [0]. The console willdisplay โMAX TIME.โ Press [ENTER]. The console will then display thecurrent time limit. Use the keypad to enter the desired time, then press[ENTER]. For no time limit, press [0].
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2. Change the units to either Metric or USA units by pressing [LEVEL: ^], [3],[1], [ENTER]. The console will display the current units - either โUSAUNITSโ or โMETRIC UNITS.โ Use the [SELECT] key to change option, andthen press [ENTER].
3. Choose the desired heart rate input preference by pressing [LEVEL: ^],[3], [2]. The console will then display โHR INPUTS.โ Press [ENTER]. Theconsole will then display the current hear rate input selection. Press the[SELECT] key to scroll through the other options. Press [ENTER] after thedesired option.
4. Change the language by pressing [LEVEL: ^], [3], [4]. The console willdisplay โLANGUAGE.โ Press [ENTER]. The console will then displaythe current language. Press the [SELECT] key to scroll through the otheroptions. Press [ENTER] to change the option.
5. Adjust the contrast on the LCD screen by pressing [LEVEL: ^], [3], [5]. Theconsole will display โCONTRAST ADJ.โ Press [ENTER]. The console willthen display the current contrast number. Press the [LEVEL: ^], and[LEVEL: โจ ] keys to increase or decrease the contrast. The changed valuewill remain on exit.
6. Reset the console to factory defaults by pressing [LEVEL: ^], [3], [9]. Theconsole will display โSET DEFAULTS .โ Press [ENTER]. Then console willrest itself and then display โDONE.โ
Quick Scan Programming
You can quickly access any of the custom menus by pressing [LEVEL: ^],[3], [ENTER]. The console will then display โCUSTOMIZE.โ Scroll through thefollowing options:
[SELECT] โ MAX TIMEโ 0[SELECT] โCHANGE UNITSโ 1[SELECT] โHR INPUTSโ 2[SELECT] โLANGUAGEโ 4
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[SELECT] โCONTRAST ADJโ 5[SELECT] โMAX SPEEDโ - N/A- 6[SELECT] โCLINICAL MODEโ-N/A- 7[SELECT] โSET DEFAULTS โ 9
Machine Status Codes
[ ^ ] [ 4 ] [ 0 ] display machine run time in hours[ ^ ] [ 4 ] [ 1 ] display number of workouts[ ^ ] [ 4 ] [ 2 ] display distance traveled[ ^ ] [ 4 ] [ 3 ] display software rev[ ^ ] [ 4 ] [ 4 ] display machine type[ ^ ] [ 4 ] [ 5 ] -N/A-[ ^ ] [ 4 ] [ 6 ] display machine run time in hours since last cleared
(used for maintenance)
1. Display the machine run time by pressing [LEVEL: ^], [4], [0]. The consolewill display โRUN HOURS XXXXXโ.
2. Display the number of workouts by pressing [LEVEL: ^], [4], [1]. The consolewill display โWORKOUTS XXXX.โ
3. Display the total distance covered up to date by pressing [LEVEL: ^], [4], [2].The console will then display โDISTANCE XXXX.โ
4. Display the console software revision number by pressing [LEVEL: ^], [4],[3]. The console will display โCONS 92111-XXX.โ
5. Display the machine type by pressing [LEVEL: ^], [4], [4]. The console willdisplay โSTEPPER (or other machine type).โ
6. Display the machine run time since last cleared by pressing [LEVEL: ^], [4],[6]. The console will display โMAINT HOURS XXXX.โ
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Quick Scan Programming
You can quickly access any of the custom menus by pressing [LEVEL: ^],[4], [ENTER]. The console will then display โMACHINE STATUS.โ Scroll throughthe following options:
[ SELECT ] โ RUN HOURS XXXXโ 0[ SELECT ] โ WORKOUTS XXXXโ 1[ SELECT ] โ DISTANCE XXXXโ 2[ SELECT ] โ CONS 90211- XXX โ 3[ SELECT ] โ STEPPERโ 4[ SELECT ] -N/A-[ SELECT ] โ MAINT HOURS xxxxโ 6
Resetting the Maintenance Hour Counter
For ease of maintenance records, the 4400/4600 PT/CL console has amaintenance timer that will clock the number of hours, workouts, and timebetween last servicing. After each maintenance period reset the counter.
[ ^ ] [ 7 ] [ 1 ] Reset Service
1. Reset the maintenance hour counter by pressing [LEVEL: ^], [7], [1]. Theconsole will dusplay โRESET SERVICE.โ Press [ENTER]. The console willdisplay โDONE.โ Press [CLEAR] to return to the starting screen.
Configuration Code
The FreeClimberยฎ console supports other StairMasterยฎ exercise systems. Itis important to verify that the machine configuration code matches the type ofmachine you have.
[ ^ ] [ 8 ] [ 0 ] Change Machine
1. Change the machine type by pressing [LEVEL: ^], [8], [0]. The console willdisplay โCHANGE MACHINE.โ Press [ENTER]. The console will then displaythe current machine type. Use the [SELECT] key to toggle betweenoptions. Press [ENTER] for the desired option.
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The StairMasterยฎ FreeClimberยฎ 4200 PT console is divided into two LCDdisplay windows. There is a four-function keypad located below the bottomwindow (see Figure 9). While you are exercising, the bottom window scrollsthrough a display of four workout statistics. An arrow on the side of each LCDwindow points to the name of what is being displayed.
Figure 9: 4200 PT Console Diagram
TOP WINDOW
The top LCD window displays information while you set up your workout. Italso displays elapsed time during your workout or during your rest period.
Workout Setup
1. While the console is in the ATTRACT mode, either press [START/STOP] or step on the pedals. Look at the top LCD window.
2. The arrow pointing to the word "Program" should be flashing and "P1"should be displayed. P1 corresponds to the MANUAL program. Usethe [+ or - ARROW] to change the workout option. "P2"
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FREECLIMBER 4200 PT CONSOLE
corresponds to Steady Pace, "P3" to Fat Burner, and "P4" to AerobicTraining. The different workout option profiles are shown on the rightside of the console.
3. When the correct workout option is displayed on the top LCD window,press [ENTER/SELECT].
4. The arrow pointing to the word "Weight" will flash and the number"150" will be displayed. Use the [+ or - ARROW] to adjust it to yourbody weight. Press [ENTER/SELECT] when it is correct.
5. If you selected a workout option other than "P1" [MANUAL], the arrowpointing to the words "Speed Level" will flash and the number "10"will be displayed. Adjust the level between 1 (the slowest) and 20 (thefastest) with [+ or - ARROW]. Press [ENTER/SELECT] when it is correct
If you selected [MANUAL], your workout will start at speedlevel 3. Level 1 is the slowest and level 20 is the fastest.Use the [+ or - ARROW] to adjust the climbing speed once yourworkout begins.
6. The arrow pointing to the word "Time" will flash and the number "15"will be displayed. Press the [+ or - ARROW] to adjust the length of yourworkout between 5 and 45 minutes.
7. Press [ENTER/SELECT]. Begin exercising.
Timer
During your workout, the top window keeps track of your workout time in min-utes and seconds. The display arrow points to the word "Time" on the console.
You may rest for up to 30 seconds at any time during your workout.Either stop stepping or press [START/STOP] to begin your rest period. To re-sume your workout, step on the pedals. If you press [START/STOP] during arest period, or if you rest for more than 30 seconds, the console will return tothe ATTRACT mode.
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BOTTOM WINDOW
The bottom LCD window keeps track of four different statistics during yourworkout: the number of calories burned, the climbing speed in steps perminute, the total number of floors climbed, and the total distance covered. Asthe console scrolls through each statistic, an arrow on the side of the displaywindow points to the name of what is being shown.
โข Calories. Provides a running total of the number of caloriesburned during a workout.
โข Steps/Min. Indicates the climbing speed based on an 8-inchstep.
โข Floors. Shows the total number of floors you have climbed.There are 16 eight-inch steps per floor.
โข Distance. Provides the equivalent horizontal distance you wouldhave traveled if you used the same amount of energy. There are48 floors per horizontal mile.
When the display arrow points to the word "Scan," all workoutstatistics are scrolled. Press [ENTER/SELECT] during your workout to lock thebottom display window on any one statistic. For instance, press [ENTER/SE-LECT] three times to lock the display on the total number of floors climbed.Press [ENTER/SELECT] two more times to resume scrolling the statistics. Dur-ing rest periods, only Calories, Floors, and Distance are shown (even if the dis-play is locked on one statistic). At the end of your workout, these same threestatistics are shown one last time.
Keypad
ENTER/SELECT. During workout setup, press this key to enter yourpersonal information and then move to the next entry. During yourworkout, press this key to lock the bottom display window on any onestatistic or to return to the scrolling mode.
+ or - ARROWS. During workout setup, press these keys to adjustyour personal information before you press [ENTER/SELECT]. Duringyour workout, use these keys to adjust the level (or climbing speed).
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START/STOP. Press this key while the console is in the ATTRACTmode to begin the workout setup. If pressed at any time duringworkout setup, all entries are cleared and workout setup starts overagain. If pressed during a workout, a 30-second rest period is started.If pressed during a rest period, the console returns to the ATTRACTmode.
QUICK START OPTION
You can quickly start the MANUAL program ("P1") by pressing[ENTER/SELECT] twice (double-clicking) at the start of workout setup.The workout statisics are based on a 150-pound person, the climbing speedstarts at level 3, and the workout time is set to 15 minutes. Use the[+ or - ARROW] to adjust the climbing speed once your workout starts.
FREECLIMBER 4200 PT CONSOLE
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HELPFUL HINTS
Read all maintenance instructions thoroughly before beginning work. In somecases, an assistant is required to perform the necessary tasks. All referencesto the right or left side and to the front or back are made as if you were on themachine ready to exercise. Major component names and locations are shownin Figure 11.
TOOL LIST
The following tools are needed to perform service and maintenance:
โข Torx screwdriver โข phillips screwdriverโข combination wrenches (sizes 7/16 - 3/4")โข wonder bar (included w/ unit)โข combination pliers โข locking pliersโข volt-ohm meter (multimeter) โข wire stripper/crimper toolโข allen wrench set (sizes 5/64 - 1/4") โข external snap ring pliersโข shop goggles or other eye protection โข torque wrenchโข socket set or nut driver set (sizes 1/4 - 3/4" in 1/16" increments)
MAINTENANCE RECORDS
For ease of maintenance the 4400/4600 PT/CL console will keep track ofhours, number of workouts, time between last servicing, etc. You can quicklyaccess any of the custom menus by pressing [LEVEL: ^], [4], [ENTER]. Theconsole will then display โMACHINE STATUS.โ Scroll through the followingoptions:
[ SELECT ] โ RUN HOURS XXXXโ* 0[ SELECT ] โ WORKOUTS XXXXโ 1[ SELECT ] โ DISTANCE XXXXโ 2[ SELECT ] โ CONS 90211- XXX โ 3[ SELECT ] โ STEPPERโ 4[ SELECT ] -N/A-[ SELECT ] โ MAINT HOURS xxxxโ 6
*The machine may show a few hours of use due to testing at themanufacturing facility.
MAINTENANCE INSTRUCTIONS
Page 40
The 4200 PT console keeps track of the number of hours the machinewas used and the total number of floors climbed. From the ATTRACT mode,press [+ ARROW] and then double-click [RESET]. The hours are shown in thetop LCD window and the total floors are shown in the bottom LCD window.
INITIAL SERVICE
Upon receiving your machine, use a soft, clean towel to wipe off the dustwhich may have accumulated during shipping. Your new machine will requireminor assembly. Refer to the โInstallation Instructionsโ section for details.
PREVENTIVE MAINTENANCE
Most of these preventive maintenance procedures can be performed afterremoving the mid-cover. The preventive maintenance schedule is summarizedin Table 3. The schedule is based on normal usage in a commercial health clubenvironment; adjust the schedule to meet actual machine usage. Refer to theโParts Removal and Replacementโ section for all disassembly and assemblyinstructions.
Cleaning
1. DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLDCLEANERs ON THE CONSOLE. Clean the console daily with a water-dampened cloth and wipe dry after cleaning.
2. Clean the exterior of the machine daily using soap and water or adiluted household cleaner such as Fantasticยฎ.
3. Thoroughly clean the entire machine, including the interior, at leastonce a week (see Table 3).
Inspecting
1. Inspect the frame for any rust, bubbling, or paint chips during theweekly cleaning. The salt in perspiration can damage the unpaintedsurfaces.
MAINTENANCE INSTRUCTIONS
Page 41
2. Inspect the Poly-V belt and HTD belts for excessive wear during thequarterly lubrication. Adjust the belt tension if necessary.
Lubrication
There are nine components that need periodic lubrication: the drive chain, thestep chains, the pedal arm return springs, the step chain connection points,the pedal arm bushings, the leveling arm bushings, the spring pulley shafts,the pedal shafts and the leveling arm pins. These parts are shown in Figure 11,page 74. Remove the bottom cover to get to the components. If you have a4600 PT/CL you will also need to remove the upper covers.
1. Place a protective mat on the floor while you lubricate your machine.A rubber floor mat is available from StairMasterยฎ Health & FitnessProducts, Inc.
2. Lubricate the drive chain and the step chains weekly. Try to penetratethe entire length of the chains with 30W motor oil.
3. Remove the drive chain and step chains every three months tothoroughly clean and lubricate them. Use a mild degreaser and astiff brush to remove dirt and corrosion from the chains.
4. Unhook the pedal arm return springs from the spring hanger everyweek. To protect them from corrosion, wipe the entire length of eachpedal arm return spring with a cloth dampened with 30W motor oilbefore reconnecting it. Replace the spring if it is rusty or otherwisedamaged.
5. Remove the double pitch master link from the step chain connectionpoints every three months. Clean the master link and the bushing inthe pedal arm. Lubricate the master link and bushing with a thin coatof multi-purpose grease before reassembling.
6. Remove the pedal arms and leveling arms every three months. Cleanthe pedal arm and leveling arm shafts and bushings with a cleancloth. Protect the shafts from corrosion by wiping them with a clothdampened with 30W motor oil.
MAINTENANCE INSTRUCTIONS
Page 42
7. Remove the spring pulleys every three months. Clean the springpulley shafts with a dry cloth. Protect the shafts from corrosion with athin coat of multi-purpose grease before reassembling.
8. Remove the pedals every three months. Clean the pedal shaft andleveling arm pin with a dry cloth. Protect the pedal shaft and levelingarm pin from corrosion with a light coat of multi-purpose greasebefore reassembling.
Battery Charge
If you have a 4600/4400 CL, remove the bottom cover and check the batteryvoltage level every three months.
1. Using your multimeter, touch the red lead to the positiveterminal of the battery and the black lead to the negative terminal.
2. If the voltage level is less than 6.1 VDC, charge the battery. Plugthe wall pack battery charger into the connector located near thebottom of the left bottom cover. Charge the battery for approximately24 to 48 hours and then recheck it. It is okay to use the machinewhile the battery charger is connected.
Battery Disposal
When ordering new batteries, you will need to properly dispose of (recycle)your old lead-acid batteries. Most federal and state regulations require lead-acid batteries to be recycled. Do not throw away old batteries. Lead is a toxicheavy metal, hazardous to living organisms. Disposal instructions and a list ofrecycling centers are tabulated in the Appendix. If you have questions, contactthe Customer Service Department at (800) 331-3578.
MAINTENANCE INSTRUCTIONS
๏ฟฝ WARNING
TO REDUCE THE POSSIBILITY OF SLIPPING, BE SURE THE PEDALAREA IS FREE OF GREASE OR OIL. WIPE ANY EXCESS OIL OFF
THE MACHINE SURFACES.
Page 43
MAINTENANCE INSTRUCTIONS
Table 3: Recommended Preventive Maintenance Schedule
*Note: Use of lubricants other than those specified will result in diminished performance and a shorter life span for that part.
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Page 44
GENERAL TROUBLESHOOTING GUIDELINES
This troubleshooting section is organized into three basic problem sections:electrical troubleshooting, console diagnostic tests, and mechanical trouble-shooting. Once you have identified the problem section, perform all the tests inthe same order as written. To order a replacement part or for help with trouble-shooting, contact our Customer Service Department. Refer to the Appendix forthe appropriate phone number.
ELECTRICAL TROUBLESHOOTING
The 4600/4400 PT electrical system has four major components: the alterna-tor, the power supply, the power cables, and the console. The 4600/4400 CLhas five major components: the alternator, the power board, the battery, thepower cables, and the console. The console, power board, and power supplyare not serviceable by the owner. If any of these parts are inoperable, theymust be replaced. Opening the console or the power supply will void thewarranty.
4600/4400 PT
1. Use a voltmeter set on VAC to verify that the AC wall outlet has 100to 120 VAC (or 220 to 240 VAC, if applicable). If you do not have avoltmeter plug in an alternate AC-powered device (e.g., a lamp). If thedevice does not work when plugged into the electrical outlet, consultan electrician for further assistance and then retest the electricaloutlet.
2. Plug the power supply into the wall outlet. The green Light EmittingDiode (LED) on the power supply should be on. If the LED does notlight up, replace the power supply.
3. Disconnect the DC cable from the left side panel. Set the voltmeter toVDC and test for 12 to 19 VDC in pins #1 (+) and #2 (-). Replace thepower supply if the voltage reading is outside the specified range.
4. Remove the bottom cover and connect the DC cable to the powerconnector on the left side of the frame. Locate the black and whitewires on the backside of the power connector.
TROUBLESHOOTING
Page 45
5. Follow the white power connector wire to the where it plugs into themain cable white wire, and disconnect it from the main cablewhite wire.
6. Set your voltmeter to VDC. Connect the positive lead of yourvoltmeter to the white wire from the power connector and touch thegray casing of the alternator with the negative lead of your voltmeter.
7. DC voltage measured should be 12 to 19 VDC. Replace the powerconnector if the voltage is not the same value as in step 3. Connectthe two white wires.
8. Remove the console knobs from the back of the console, lift theconsole up, and disconnect the 20-pin main cable from the console.
9. Test for 12 to 19 VDC in pins #1 (-) and #10 (+) in the main cableconnector. Replace the main cable if the voltage reading is notthe same as in step 7.
10. If all voltage readings have been within the specified range and theconsole will not power up, the console should be replaced.
Alternator Test
11. Check for loose wiring connections on the alternator, diode, and loadresistor (see Final Assembly Figure).
12. Perform the Positive Output to Field test on the alternator:
โข Disconnect the power cord from the electrical outlet.โข Remove the black wire from the B+ terminal on the alternator.โข Remove the brown wire from the field terminal on the alternator.
ELECTRICAL TROUBLESHOOTING
Page 46
โข Place a short wire with alligator clips on the B+ terminal and thefield (FLD) terminal of the alternator.
โข Step on the machine for approximately 10 to 15 seconds.โข If full resistance is achieved during this time, your alternator
has correct current flow. If no resistance is achieved, replacethe alternator.
Diode Test
13. Remove the brown wire and diode from the field terminal of thealternator and set your voltmeter to the Ohms setting.
14. Place one lead from the voltmeter on each end of the diode, and thenreverse the leads. A diode that is good will show a high reading inone direction and a low reading when the leads are reversed.Replace the diode if the readings recorded are both high or both low.
Resistor Test
15. Remove one wire from the load resistor (see Final Assembly Figure)and place one lead from the voltmeter on each of the threaded postson the load resistor. Replace the load resistor if the voltmeter doesnot read 0.5 Ohms (ยฑ 10%).
4600/4400 CL
Battery Test
1. Remove the mid cover and top covers and unplug the battery fromthe power control board. Locate pins #1 & 2 in the end of the cable.Use a voltmeter to verify that the voltage is a minimum of 6.1 VDC.Reconnect the battery back to the power control board and install thebattery charger for at least 24 hours if the voltage measured is below6.1 VDC. Note: You can use the machine while the battery rechargeris connected.
2. Remove the console knobs from the back of the console, lift theconsole up, and disconnect the main cable from the console.
ELECTRICAL TROUBLESHOOTING
Page 47
3. Step up on the machine. With the voltmeter set to DC voltage, testfor greater than 6.1 VDC in pins #1 (+) and #10 (-) in the main cableconnector while stepping. Replace the main cable if the voltagereading is less than 6.1 VDC. Next, check for continuity in the maincable (see Final Assembly Figure).
4. If all voltage readings have been within the specified range and theconsole will not power up, the console should be replaced.
Alternator Test
5. Perform the Positive Output to Field test on the alternator:
โข Unplug the battery from the power control board.โข Remove the black wire from the B+ terminal on the alternator.โข Remove the brown wire from the field terminal on the alternator.โข Place a short wire with alligator clips on the B+ terminal and the
field (FLD) terminal of the alternator.โข Step on the machine for approximately 10 to 15 seconds.โข If full resistance is achieved during this time, your alternator
has correct current flow. If no resistance is achieved, replacethe alternator.
Resistor Test
6. Unplug the load resistor from the power control board and set yourvoltmeter to Ohms. Place one lead from the voltmeter on each of thethreaded posts on the load resistor. Replace the load resistor if thevoltmeter does not read 2.5 Ohms (ยฑ 10%).
7. If the problem still exists, contact the Customer Service Department at800-331-3578.
ELECTRICAL TROUBLESHOOTING
Page 48
The following tests are performed while the console is in the โSELECTWORKOUTโ mode. If the console fails any test, the console should be replacedor exchanged. To return to the โSELECT WORKOUTโ mode, press either[CLEAR] or [START/STOP] while in the DIAGNOSTIC mode. Please note thatthere may be additional verbiage on the display other than is listed in thismanual. The FreeClimber console is used on other StairMasterยฎ equipment.
DIAGNOSTIC CODES
[ ^ ] [ 6 ] [ 0 ] Test display[ ^ ] [ 6 ] [ 1 ] Test keyboard[ ^ ] [ 6 ] [ 2 ] Test serial port[ ^ ] [ 6 ] [ 3 ] Test alternator[ ^ ] [ 6 ] [ 4 ] -N/A-[ ^ ] [ 6 ] [ 5 ] -N/A-[ ^ ] [ 6 ] [ 6 ] Test Tach[ ^ ] [ 6 ] [ 7 ] - [ 6 ] [ 9 ] -N/A-
Display Test
During the display test, the console screen alternates between all LCDsegments turned on and the sample program profile screen at a 2-second rate.
1. Press [ LEVEL: ^ ], [ 6 ], [ 0 ], [ENTER]. The console will displayโDISPLAY TESTโ.
2. All LCD segments will turn on for 2 seconds, and then a sampleprogram profile will be displayed for 2 seconds. Press [CLEAR] to endthe test.
Keypad Test
Perform this test if you are having trouble entering data into the console.During the test, pressing any key displays that key name on the message line.Press [CLEAR] to exit.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS
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1. Press [ LEVEL: ^ ], [ 6 ], [ 1 ], to start the test.
2. Firmly press each button except [CLEAR]. The name of the key will beshown in the display window. Press [CLEAR] to end the test.
Serial Port Test
This test verifies that the RS 232 port used for linking to external C.S.A.F.E.systems (commercial entertainment systems) is working. You must have theloop-back cable assembly (PN 040051-001) to perform this test.
1. Insert the loop-back cable assembly into the RS 232 port on the backof the console.
2. Press [ LEVEL: ^ ], [ 6 ], [ 2 ]. The console will display โSERIAL TESTS.โPress [ENTER] to access the C.S.A.F.E. test.
3. Press [ENTER] a second time. The console will run a diagnostic testand then display either โPASSโ or โFAIL.โ Replace the console if itfails this test.
Alternator Test
Use this test to verify the alternator field routines of the console. You will needto briefly exercise on the machine for this test.
1. Press [ LEVEL: ^ ], [ 6 ], [ 3 ], to start the test.
2. For โField onโ press [ LEVEL: ^]. Step on the machine forapproximately 10 to 15 seconds. If full resistance is achieved duringthis time, your console has correct current flow. If no resistance isachieved, either the console or the alternator is bad. See theelectrical troubleshooting portion of this manual to isolate and testthe alternator. Replace the console if the alternator is good.
3. For โField offโ press [ LEVEL: V]. Step on the machine forapproximately 10 to 15 seconds. You should not get resistance withthe field turned off. Press [CLEAR] to end the test.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS
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Tach Test
If you do not have resistance, perform the tach test. The tach test will tell youthe tach signal, in revolutions per minute (RPMs), picked up by the console.
1. Press [ LEVEL: ^ ], [ 6 ], [ 6 ], [ENTER]. The console will displayโTAR TACH ACT.โ The target tach speed of 2,000 RPMs will be shownin the upper left corner of the display window. The actual tach pickedup by the console will be shown in the upper right corner of thedisplay window.
2. Start stepping on the pedals. The number in the right hand corner ofthe console should increase to 2,000 RPMs (+/- 200). If the tach signalpicked up by the console is less then 1,900 RPMs then there is aproblem in the AC tach circuit - either with the console software,alternator (check the AC tach wire, the field wire, the diode, and theterminal posts), or the main cable.
Error Reporting
The console will display various error messages in the display window. Thetotal amount of errors will be displayed in the upper right numeric window.Note that only the highest priority reported error will be displayed. Errors arehandled in two ways. One as a non-fatal โWARNINGโ which will display thetext message but continue system operation until the user presses the [CLEAR]key. The second way is as a fatal โERRORโ which will stop the exercise andreturn the system to an idle intensity state. The console will display the errortext and not let the user restart the programs unless power has been turnedoff and then back on.
The following microprocessor errors require a console replacement;ALU ERROR, TIMER ERROR, and STATIC RAM ERROR.
Resetting the power may clear the following microprocessor errors;EEPROM ERROR, and PROGRAM ERROR. If resetting the power doesnโt work,the console may need to be replaced.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS
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Contact Heart Rate Test
The contact heart rate system is made up of the console and the contactheart rate sensor handles. Remember that even when operating properly, thecontact Heart Rate system will not work for everyone. If you suspect you havea problem with your system, have someone else try it before performing thefollowing troubleshooting steps:
1. With the console showing โSELECT WORKOUT,โ place your handson the sensor handles using a relaxed grip, and remain still. Afterapproximately 10 seconds a flashing โฅ should be displayed on theconsole, followed by your heart rate in beats per minute. If your heartrate does not appear, continue on to the next step.
2. Verify that the console software has been set up to receive contactheart rate (see the heart rate monitoring section of this manual).
3. If the telemetry (Polarยฎ) receiver located in the console is receivinginterfering signals, the contact heart rate system may be inhibited.Take your hands off the handle sensors for about 20 seconds andwatch the heart display. If it flashes on and off, the telemetry heartrate is picking up interfering signals, and the machine must be movedaway from the source of the interference or the telemetry heart rateinput must be disabled (see the heart rate monitoring section of thismanual).
4. Remove the console knobs from the back of the console, lift theconsole up, and disconnect both the main cable and the small handgrip sensor cable from the console. Use an ohmmeter to check forcontinuity between the hand grip sensors and the small cableconnector. If the handles are working, each steel sensor should beconnected to one wire on the cable connector, with less than 15 ohmsshowing on the ohmmeter.
5. If possible, replace or exchange your console with a console that youknow is working and retest the machine.
6. If the problem still persists, contact the Customer Service Departmentat 800-331-3578.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS
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Telemetry (Polarยฎ) Heart Rate Test
The telemetry heart rate system is made up of the console, the heart rate re-ceiver, and the chest strap (available separately). You can test each compo-nent by performing the following steps:
1. You will need to put a chest strap on to test the telemetryheart rate. Before you put on the chest strap, wet the two contactpatches. Secure the chest strap as high under your pectoral muscles(chest) as is comfortable. The chest strap should fit snugly,
comfortably, and allow normal breathing.
2. A flashing โฅ should be displayed on the console. Your heart rate, inbeats per minute, will show next to the heart icon. If the heart icondoes not show, or if your heart rate is not displayed on the console,then you have a problem with either the console, chest strap, orheart rate receiver.
3. Verify that the console software has been set up to receive telemetry(see the heart rate monitoring section of this manual). Note thatholding the contact heart rate sensors (if enabled) can inhibit thetelemetry heart rate input from working.
4. Test your chest strap with a machine that you know is working orwith a heart rate watch that you know is working.
5. External interference caused by nearby televisions, personal CDplayers, or air conditioners may also inhibit the telemetry heart ratepickup. Move the machine away from interference sources if possible.
6. If possible, replace or exchange your console with a console that youknow is working and retest the machine.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS
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If you hear a grinding or clicking noise, experience excessive vibration duringexercise, or if the pedals are not functioning properly, you probably have aproblem in the drive train. Attempt to isolate the problem area by performingthe following tests in precisely the order listed below. Refer to the โParts Re-moval and Replacementโ section for all disassembly and assembly instruc-tions.
1. Unplug the machine and remove the bottom side covers.
2. Noise can be generated by a Poly-V or HTD belt that is either too tightor too loose. Check the condition and the tension of the belts. Re-place worn belts. Adjust the belt tension according to the instructionsin the "Parts Removal and Replacement" section.
3. Remove the Poly-V belt and move the pedal arms. If the noise nolonger exists, check the condition of the alternator. If the noise is stillpresent, go to step #4.
โข Disconnect the DC power cable if you have a 4600/4400/4200 PTor unplug the connector from position J4 on the power supplycircuit board if you have a 4600/4400 CL. Spin the alternatorpulley with your fingers. It should spin freely and remain spinningfor at least two revolutions. If it does not, the alternator should bereplaced.
โข If the alternator does spin freely, check the alternator for noise,roughness, or the presence of an excessive amount of blackpowder inside the alternator or near the outside of the case. Ifany of these conditions exist, the brushes might be bad and thealternator should be replaced.
MECHANICAL TROUBLESHOOTING
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINEWHILE THE COVERS ARE REMOVED. DO NOT DEPRESS OR RAISE THE PEDALS WHILE
ANYONE'S HANDS ARE INSIDE THE MACHINE.
๏ฟฝ ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ
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โข Do not reinstall the Poly-V belt if performing step #4. Plug in theconnector at position J4 or reconnect the DC power cable,as applicable.
4. Remove the drive and step chains. Check the condition of the chainsby flexing each link up and down. Each link should move freely. Re-place the chain if any stiff or inflexible links are found or if the chain isrusty, corroded, or otherwise damaged. Do not reinstall the chains.
5. Remove the pedals. Clean any corrosion off the pedal shaft with anoil-dampened rag. Apply a thin coat of multi-purpose grease to theshaft. If the noise persists, go to step 6.
6. Check the step chain connection point. Clean and grease the masterlink and bushing. Replace damaged parts.
7. Check the drive hub assembly.
โข Check the condition of the drive sprocket teeth. The teeth shouldnot be unevenly worn. Replace the worn sprocket(s).
โข The drive sprockets work independently of one another. Eachsprocket should turn freely in one direction and lock when turnedin the other direction. Replace an inoperable drive sprocket.
โข Remove the drive shaft. Inspect the bearings in the drive hub.Replace the drive hub assembly if the shaft does not spin freelyor if there is excessive radial play at the shaft. Be careful not toget dirt into the hub.
โข Inspect the ends of the drive shaft (at the sprocket attachmentpoints) for signs of wear or scoring. Replace the shaft if it isexcessively worn.
8. Check the pedal arm and leveling arm shafts by removing both theright and left pedal and leveling arms. Inspect the shafts and thebushings for signs of wear and corrosion. Replace the bushing(s) ifworn.
MECHANICAL TROUBLESHOOTING
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โข Clean all corrosion off the pedal arm shaft and leveling arm shaftand bushings. Wipe the shafts with an oil-dampened cloth beforereassembling. DO NOT SAND THE PEDAL ARM SHAFT ORLEVELING ARM SHAFT.
9. Remove the HTD belt. Inspect the belt, the Poly-V pulley, and the HTDpulley for excessive wear. Replace if necessary. The Poly-V pulleyshould spin freely. If it does not, replace the eccentric shaft assembly.
10. Inspect the HTD pulley for excessive wear and smoothness ofoperation. If the pulley is worn, replace it. If it does not spin freely,remove the first reduction shaft and inspect the bearings.
11. Reinstall all parts, ensuring the proper tension of the Poly-V and HTDbelts and the drive chain (see Figure 30). Clean and lubricate the driveand step chains with 30W motor oil before reinstalling them.
MECHANICAL TROUBLESHOOTING
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COVERS
There are three covers on the 4400 PT/CL and the 4200 PT: the top cover, themid-cover and the bottom cover. The top and bottom covers are made of aright and left section. Do not separate the right and left sections of either thetop or bottom covers to perform most maintenance tasks. Access to the interiorof the machine takes three steps: remove the mid cover, slide the top coverupward, and remove the bottom cover (see Figure 24).
The 4600 PT/CL has an additional shield over the handles. Access tothe interior of the machine takes four steps: remove the mid cover, remove theshield, separate the top covers, and remove the bottom cover.
Mid Cover
1. Use the fastener removal tool to remove each of the four fastenerpins on the mid cover (see Figure 23).
2. Stand on the pedals and keep them on the floor.
3. Slide the mid cover down and away from the machine. Removethe cover from the frame tube. Carefully let both pedals return tothe upper stops.
Top Cover
1. 4400 PT/CL, 4200PT: Remove the mid cover and the console.
2. Release the pins along the middle seam of the top cover. Use asmall phillips screwdriver or similar tool to push the fastener centerpin in at least halfway. Use your fingers to remove the fastener basefrom the cover and then separate the top covers.
PARTS REMOVAL AND REPLACEMENT
๏ฟฝ ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINEWHILE THE COVERS ARE REMOVED. DO NOT DEPRESS OR RAISE THE
PEDALS WHILE ANYONE'S HANDS ARE INSIDE THE MACHINE.
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3. 4600 PT/CL: Use the fastener removal tool to release the coverfasteners and separate the top covers.
4. To reinstall the 4400 PT/CL and 4200 PT fasteners, remove the pincompletely from the base. Insert the base into the hole in the covers.Insert the pin into the base until it is flush with the base.
Shield (4600 PT/CL )
1. Remove the two mountingscrews from the bottom shield.
2. Separate the top shield from thebottom shield and remove theupper and lower shield from thehandrail.
Bottom Cover
1. Remove the mid cover.
2. 4600/4200/4400 PT: Disconnect the DC power cable from theconnector located on the bottom side of the left bottom cover.
3. Remove the fastener located on each side of the lower edge ofthe bottom cover (see Figure 24).
4. 4400/PT/CL, 4200 PT: Kneel in front of the machine, facing the coverseam. Push in and hold both sides of the lower cover to disengagethe locking tabs at the joint between the upper and lower covers. Useyour hands to push up the top cover and separate the top cover fromthe bottom cover. Pull out and forward on the lower cover to remove itfrom the frame.
4600 PT/CL: Remove the cover fasteners and separate the left andright top cover from each other. Pull out and forward on the lowercover to remove it from the frame.
PARTS REMOVAL AND REPLACEMENT
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CONSOLE
1. Remove the four mounting knobs from the back of the console.
2. Disconnect the main cable, contact heart rate cables (4600 PT/CL),and Polarยฎ cable (4600/4400 PT/CL) from the back of the console. Liftthe console off the machine.
3. Reverse the steps to reinstall the console.
CONSOLE ADJUSTMENT
1. Loosen the console bracket wing nut.
2. Pivot the console up or down to adjust theconsole to desired viewing angle and thentighten the wing nut.
POLY-V AND HTD BELT
1. Remove the bottom cover.
2. Loosen the adjustment bolt that mounts the alternator to theslotted alternator brace and the pivot adjusting bolt and nut. Swingthe alternator down.
3. Remove the Poly-V belt.
4. Slide the HTD belt toward you and off the HTD pulley. Remove thebelt from the machine.
5. Reinstall the HTD belt.
PARTS REMOVAL AND REPLACEMENT
๏ฟฝ WARNING
THE BELTS MUST BE PROPERLY TENSIONED. A BELT THAT IS TOO TIGHTWILL CAUSE SLOW AND SLUGGISH OPERATION. A BELT THAT IS TOO LOOSE
WILL CAUSE EXCESSIVE NOISE AND BELT WEAR.
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6. Adjust the HTD belt tension so that you have 1/4 inch (0.6 cm) of side-to-side play with fingertip pressure (see Figure 30). The bottom shaftis mounted in an eccentric hub. To adjust the tension:
โข Loosen and remove the four bolts and nyloc nuts from the hub.โข Turn the hub one hole clockwise.โข Install and tighten the four bolts and nyloc nuts.โข Verify the HTD belt tension.
7. Install the Poly-V belt. Make sure it is centered on the pulleys.
8. Pivot the alternator up or down as necessary to allow 1/4"(0.6 cm) of belt deflection with fingertip pressure at the center of thevertical portion of either side of the belt (see Figure 30).
9. Tighten the alternator adjustment bolt. Verify 1/4" (0.6 cm) of playin the belt and reinstall the bottom cover.
STEP CHAIN RETAINER
1. Remove the bottom cover.
2. Loosen and remove the two step chain retainer bolts. These bolts arealso the top two mounting bolts for the drive hub assembly.
3. Reverse the removal procedures to install the step chain retainer.Make sure there is adequate clearance between the step chain andthe step chain retainer.
PEDAL ARM RETURN SPRING
1. Remove the bottom cover.
2. Unhook the pedal arm return spring from the spring hanger.
3. Detach the spring from the step chain by removing the master link.The spring-chain connector is in good condition if it has an hour glassshape. Replace a worn spring-chain connector.
PARTS REMOVAL AND REPLACEMENT
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4. Check to ensure that the spring pulley turns freely and is not wornexcessively. Refer to the โSpring Pulleyโ section if you have to replacethe pulley.
5. To reinstall the spring, connect it to the end of the step chain usingthe master link.
6. Route the spring under the spring pulley that is fastened to the springpulley shaft (see Figure 11).
7. Hook the end of the pedal arm return spring onto the spring hanger.
8. Reinstall the covers.
STEP CHAIN
1. Remove the bottom cover.
2. Remove the step chain retainers.
3. Support the pedal arm. Unhook the pedal arm return spring from thespring hanger. Lift the step chain up and off the clutch sprocket andlower the pedal arm to the floor.
4. Remove the double-pitch master link (PN 21298SV) and bearingsleeve assembly from the step chain connection point on the pedalarm.
5. Remove the master link from the spring-chain connection.
6. Reverse the procedures to reinstall the step chain. Lubricate the stepchain before reinstalling the covers.
PARTS REMOVAL AND REPLACEMENT
๏ฟฝ WARNING
DO NOT TWIST THE SPRING DURING INSTALLATION. IT WILL WEAREXCESSIVELY AND REDUCE THE LIFE OF THE SPRING.
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SPRING PULLEY
1. Remove the bottom cover.
2. Unhook the pedal arm return spring from the spring hanger.
3. Remove the snap ring from the pulley shaft (see Figure 11).
4. Slide the pulley and washer off the shaft.
5. Before reinstalling the pulley, clean the pulley shaft thoroughly witha clean, dry cloth. Apply a thin coat of multi-purpose grease to thepulley shaft.
6. Slide the pulley and washer onto the shaft. Install the snap ring.
7. Route the spring under the spring pulley.
8. Hook the end of the spring over the spring hanger. Do not twist thespring.
9. Reinstall the covers.
DRIVE CHAIN
1. Remove the bottom cover.
PARTS REMOVAL AND REPLACEMENT
TO REDUCE THE RISK OF EYE INJURY, WEAR EYEPROTECTION WHEN REMOVING SNAP RINGS.
๏ฟฝ WARNING
๏ฟฝ WARNING
DO NOT TWIST THE SPRING DURING INSTALLATION. IT WILL WEAREXCESSIVELY AND REDUCE THE LIFE OF THE SPRING.
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TO REDUCE THE RISK OF EYE INJURY, WEAR EYEPROTECTION WHEN REMOVING SNAP RINGS.
๏ฟฝ ๏ฟฝ๏ฟฝ ๏ฟฝ๏ฟฝ๏ฟฝ
2. Remove the master link from the drive chain.
3. Remove the drive chain from the sprockets.
4. Reinstall the drive chain, ensuring the master link is properly installed.
5. Check the drive chain tension. There should be a total of 1 to1-1/2" (2.5 to 4.0 cm) of play, up and down, at the slackest point in thechain (see Figure 27). If the drive chain tension needs adjustment,refer to the โDrive Hub Assemblyโ section.
6. Lubricate the chain with 30W motor oil and wipe off the excess.
7. Reinstall the covers.
DRIVE SHAFT ASSEMBLY
1. Remove the bottom cover.
2. Remove the step chain retainers.
3. Support the pedal arm. Unhook the pedal arm return spring from thespring hanger. Lift the step chain up and off the clutch sprocket andlower the pedal arm to the floor. Repeat on the other side.
4. Remove the snap ring from the left end of the drive shaft.
PARTS REMOVAL AND REPLACEMENT
๏ฟฝ WARNING
IF THE DRIVE CHAIN IS TOO TIGHT, THE DRIVE TRAIN WILL WEAREXCESSIVELY, SHORTENING THE LIFE OF THE DRIVE HUB. IF THECHAIN IS TOO LOOSE, THE MACHINE WILL BE NOISY AND WILL
OPERATE AT LESS THAN PEAK EFFICIENCY.
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5. Remove the drive chain.
6. Remove the sprocket and the other small parts from the left side ofthe hub assembly (see Figure 18).
7. Slide the drive shaft to the right, out of the hub assembly. If youremove the right-hand clutch sprocket from the drive shaft, do notconfuse it with the left-hand clutch sprocket.
8. Loosen and remove the two remaining bolts and nuts that hold thehub assembly to the frame. Remove the hub assembly.
9. Inspect the drive shaft, the bushings, the thrust washers, andclutch sprockets for excessive wear or pitting. Replace worn-outcomponents.
10. To reinstall the hub assembly, carefully reverse the disassemblyprocedures. Be sure that the right- and left-hand clutch sprockets arepositioned correctly; the wide shoulder of the sprocket should befacing away from the hub on both sides.
11. Chain Tension. The drive shaft is mounted in an eccentric hub.Rotate the hub so the marked hole is in the 12 oโclock position, liningup four holes in the hub with the four holes in the frame. Use this hubposition when reinstalling the drive chain since the distance betweenthe drive and transmission shafts is at a minimum. The hub is in theproper position when the drive chain has a total of 1 to 1-1/2" (2.5 to4.0 cm) of play at the slackest point. As the drive chain stretches withuse, increase the chain tension (and the distance between the twoshafts) by rotating the hub counterclockwise (see Figure 26). Thedistance between the two shafts is greatest when the marked hole inthe hub is at the 8 oโclock position.
12. Reinstall the covers.
PARTS REMOVAL AND REPLACEMENT
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PEDAL
1. Remove the snap ring and flat washer from the leveling arm pin andthe pedal shaft (see Figure 17).
2. Slide the pedal off the shaft.
3. Clean the pedal shaft and leveling arm pin with a dry cloth. Lubricatethe pedal shaft and the leveling arm pin with a thin coat of multi-purpose grease.
4. Reverse the procedures to reinstall the pedal.
LEVELING ARM
1. Remove the pedal.
2. Remove the bottom cover.
3. Remove the snap ring that secures the leveling arm to the levelingarm shaft (see Figure 19).
4. Slide or gently tap the leveling arm off the shaft.
5. Clean the shaft and the pin with a cloth dampened with 30W motoroil before reassembly.
6. Reverse the removal instructions to reinstall the leveling arm.
PARTS REMOVAL AND REPLACEMENT
TO REDUCE THE RISK OF EYE INJURY, WEAR EYEPROTECTION WHEN REMOVING SNAP RINGS.
๏ฟฝ WARNING
TO REDUCE THE RISK OF EYE INJURY, WEAR EYEPROTECTION WHEN REMOVING SNAP RINGS.
๏ฟฝ WARNING
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PEDAL ARM
1. Remove the pedal and the bottom cover.
2. Remove the step chain retainers.
3. Support the pedal arm. Unhook the pedal arm return spring from thespring hanger. Lift the step chain up and off the clutch sprocket andlower the pedal arm to the floor.
4. Remove the master link from the step chain connection point.
5. Remove the snap ring from the pedal arm mounting shaft and theleveling arm pin.
6. Slide or gently tap the pedal arm off the mounting shaft.
7. Clean the pedal arm shaft and leveling arm pin with a clothdampened with 30W motor oil before reassembly.
8. Reverse the removal procedures to reinstall the pedal arm.
PEDAL PAD
1. The pedal pad wraps around the pedal and locks into place under thepedal. Separate the pedal pad from the pedal by grabbing the bottomof the pedal and pulling down and out.
2. Lift the other side of the pedal pad up and remove the pedal pad fromthe pedal.
Note: There is a right and left pedal pad. Do not install a leftpedal pad on a right pedal, or a right pedal pad on a left pedal.
PARTS REMOVAL AND REPLACEMENT
TO REDUCE THE RISK OF EYE INJURY, WEAR EYEPROTECTION WHEN REMOVING SNAP RINGS.
๏ฟฝ WARNING
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PARTS REMOVAL AND REPLACEMENT
ECCENTRIC HUB ASSEMBLY
1. Remove the bottom cover.
2. Remove the Poly-V and HTD belts.
3. Loosen and remove the four nyloc nuts and bolts from the hub.Remove the assembly from the frame.
4. Reassemble in the reverse order. Ensure the belts are properlytensioned; refer to the "Poly-V and HTD belt" section.
FIRST REDUCTION SHAFT ASSEMBLY
1. Remove the bottom cover.
2. Remove the drive chain.
3. Remove the eccentric shaft assembly.
4. Remove the set screw from the transmission sprocket (see Figure 21).Remove the sprocket and key from the shaft.
5. Hold onto the HTD sprocket and pull the shaft out of the hub.
6. Reassemble in the reverse order. Ensure the belts are properlytensioned; refer to the "Poly-V and HTD belt" section.
HANDLEBAR (4400 PT/CL ,4200 PT)
1. Remove the console and separate the left and right top cover.
2. Cut the Ty-wraps that secure the main cable to the handlebar tube.
3. Remove the four screws and flat washers that hold the handlebartube in the frame tube.
4. Lift the handlebar out of the frame. Reverse the steps to reinstall thehandlebars.
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UPPER HANDLES (4600 PT/CL)
1. Disconnect the left and right contact heart rate cables from the backof the console.
2. Remove the two mounting screws from the top and bottom shieldand remove the shields from the upper handle assembly.
3. Remove the four handrail adapter screws from the upper handleassembly.
4. Remove the upper handle assembly from the machine. The contactheart rate cables are threaded through the handrail adapter. Removethe handrail adapter from the contact heart rate cables.
5. Reverse the removal procedures to install the new upper handleassembly.
SIDE HANDRAILS (4600 PT/CL)
1. Disconnect the left and rightcontact heart rate cablesfrom the back of the console.
2. Remove the two mountingscrews from the top and bottomshield (see Figure 20) and removethe shields from the upper handleassembly.
3. Remove the four handrailadapter screws from the upperhandle assembly.
4. Remove the upper handle assemblyfrom the machine. The contact heart ratecables are threaded through the handrailadapter. Remove the handrail adapter from thecontact heart rate cables. Set the upper handle assembly aside.
PARTS REMOVAL AND REPLACEMENT
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PARTS REMOVAL AND REPLACEMENT
5. Tilt the machine forward and use an extended socket to remove thetwo handrail adapter screws from the front leg of the machine.
6. Tilt the machine back into place and pull each handrail out sideways.Be aware that the handrail extrusion connects the left handrail to theright handrail, and may fall out when one side is removed.
7. Reverse the removal procedures to reinstall the handrail.
ALTERNATOR
1. Remove the bottom cover. Mark (by color) the location of each wireattached to the alternator (see Final Assembly Diagram). Remove thewires from the alternator.
2. Loosen and remove the alternator adjusting bolt on the slotted brace.Remove the Poly-V belt. Inspect the belt for wear and replace the beltif it is cracked, cut, or is otherwise damaged.
3. Loosen and remove the nyloc nut from the alternator post. Removethe alternator from the frame.
4. Reverse the removal procedures to install the new alternator. Be sureto verify the wiring against the Final Assembly Diagram.
5. Pivot the alternator up or down as necessary to allow 1/4"(0.6 cm) of belt deflection with finger tip pressure at the center of thevertical portion of either side of the belt (see Figure 27).
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The machine must be grounded if you are using the external power supply orthe battery charger. Grounding provides the path of least resistance for theelectric current, thereby reducing the risk of electric shock. The power supplyor battery charger must be plugged into an appropriate outlet that is properlyinstalled and grounded in accordance with all local codes and ordinances.
The grounding plug on the power supply and the battery charger isshown in sketch A below*. A temporary adapter, shown in sketches B and C,may be used to connect the plug to a two-pole receptacle if a properlygrounded outlet is not available. The adapter should be used only until a prop-erly grounded outlet (sketch A) can be installed by a qualified electrician. Thetab extending from the adapter must be connected to a permanent groundsuch as the metal screw on the outlet cover.
* This may vary for International power supplies.
GROUNDING INSTRUCTIONS
Figure 10: Grounding System
๏ฟฝ DANGER
IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING CONNECTOR CANRESULT IN THE RISK OF ELECTRIC SHOCK. CHECK WITH A QUALIFIED ELECTRI-CIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE MA-CHINE IS PROPERLY GROUNDED. DO NOT MODIFY THE PLUG PROVIDED WITHTHIS MACHINE. IF IT WILL NOT FIT THE AVAILABLE OUTLET, HAVE A PROPER
OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN.
Page 70
This equipment has been tested and found to comply with the limits for aClass B digital device, pursuant to Part 15 of the FCC rules. These limits aredesigned to provide reasonable protection against harmful interference in aresidential installation. This equipment generates, uses and can radiate radiofrequency energy and, if not installed and used in accordance with the instruc-tions, may cause harmful interference to radio communications. However,there is no guarantee that interference will not occur in a particular installa-tion. If this equipment does cause harmful interference to radio or televisionreception, which can be determined by turning the equipment off and on, theuser is encouraged to try to correct the interference by one or more of the fol-lowing measures:
โข Reorient or relocate the receiving antenna.โข Increase the separation between the equipment and receiver.โข Connect the equipment into an outlet on a circuit different from
that to which the receiver is connected.โข Consult the dealer or an experienced radio/TV technician for help.
CANADIAN DOC CLASS B COMPLIANCE
This digital apparatus does not exceed the Class B limits for radio emissionsfrom digital apparatus set out in the radio interference regulations of the Ca-nadian Department of Communications.
La prรฉsent appareil numรฉrique ne dรฉpasse pas les limites etablies pour lesbruits radioรฉlectriques applicables aux appareils numรฉriques de la Class Bprescrites dans les rรจglement sur le brouillage radioรฉlectrique รฉdictรฉ par leMinistรจre des Communications du Canada.
FCC COMPLIANCE
๏ฟฝ WARNING
CHANGES OR MODIFICATIONS TO EQUIPMENT NOTEXPRESSLY APPROVED BY STAIRMASTERยฎ HEALTH & FITNESS
PRODUCTS, INC. COULD VOID THE USER'S AUTHORITY TOOPERATE THIS EQUIPMENT.
Page 71
APPENDICES
If you need assistance, please have both the serial number of your machineand the date of purchase available when you contact the appropriateStairMasterยฎ Health & Fitness Products, Inc. office listed below.
OFFICES IN THE UNITED STATES
CORPORATE HEADQUARTERS CUSTOMER SERVICE12421 Willows Road NE, Suite 100 12421 Willows Road NE, Suite 100Kirkland, WA 98034 Kirkland, WA 98034(800) 635-2936 or (425) 823-1825 (800) 331-3578FAX: (425) 823-9490 FAX: (425) 814-0601www.stairmaster.com E-mail: customerservice@
stairmaster.com
INTERNATIONAL OFFICES AND DISTRIBUTORS
For technical assistance and a list of distributors in your area, please call or faxone of the following numbers.
INTERNATIONAL DIVISION ASIA PACIFIC HEADQUARTERS(425) 823-1825 Telephone/Fax:+81-45-590-5686FAX: (425) 820-7505 E-mail: [email protected]: [email protected]
EUROPE: HEADQUARTERS+41-91-827-3801FAX: +41-91-827-8902E-Mail: [email protected]
GERMANY: HEADQUARTERS+49-2204/610-27FAX: +49-2204/628-90E-Mail: [email protected]
U.K.: HEADQUARTERS+44-1908/267-345FAX: 44-1908/267-346E-mail: [email protected]
Page 72
BATTERY RECYCLING
After installing a new battery, Contact the nearest Yuasa-Exide, Inc. recyclingcenter from the list below to get information on the proper disposal of your oldlead-acid battery. Most federal and state regulations require lead-acid batter-ies be recycled. Do not throw away old batteries. Lead is a heavy metal and istoxic to living organisms.
STATE ADDRESS PHONE NUMBER
Alabama 906 40th St. (205) 591-0606Birmingham, AL 35222
California, 3470 Depot Rd. (510) 887-8080 (Northern) Hayward, CA 94545 California, 1250 Bixby Dr. (818) 333-3060 (Southern) City of Industry, CA 91745 Colorado 12860 W. Cedar Dr. (303) 763-5833
Suite 106ALakewood, CO 80228
Florida 11310 Satellite Blvd. (407) 857-9234Orlando, FL 32821
Georgia 1721-C Oakbrook Dr. NE (404) 446-8663Norcross, GA 30093
Illinois 5303 Ninth Ave (708) 352-3665Countryside, IL 60525
Maryland 899 Airport Rd. Ste E (410) 768-5586Glen Burnie, MD 21061
Massachusetts 13 Wheeling Ave. (617) 932-6570Woburn, MA 01801
Michigan, 2760 Auburn Rd. (616) 531-1120 Southeast Auburn Hills, MI 48326 Michigan, West 2882 Remico St. SW (612) 631-2150
Grandville, MI 49418 Minnesota 1900 Oakcrest Ave. Ste 5 (816) 231-1414
Roseville, MN 55113 Missouri 5328 Winner Rd. (816) 231-0685
Kansas City, MO 64127 New Hampshire 17 Clinton Dr. (603) 886-5900
Hollis, NH 03049
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โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ
โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ
โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ
โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ
APPENDICES
Page 73
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โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ
โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ
โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ
โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ โ
STATE ADDRESS PHONE NUMBER
New Jersey 131 Industrial Ave. (201) 641-5900Hasbrouck Hgts., NJ 07604
New York 26 Corporate Circle (315) 437-1788E. Syracuse, NY 13057
Ohio, Central Rickenbacker ANG (513) 851-3838Bldg. 1073Columbus, OH 43217
Ohio, North 2635 Hamilton Ave. (216) 241-6231Cleveland, OH 44114
Ohio, Southwest 540 Northland Blvd. (216) 241-6231Cincinnati, OH 45240
Pennsylvania, East 3000 Montrose Ave. (215) 921-4480Laureldale, PA 19605
Pennsylvania, East 320 Constance Dr. (215) 443-0912Warminster, PA 18974
Pennsylvania, West 920 Vista Park Rd. (412) 788-1613Pittsburgh, PA 15205
Tennessee 2934 Brooks Road (901) 396-5031Memphis, TN 38116
Texas, Northeast 11420 Ferrell Dr. Ste 300 (214) 869-1855Dallas, TX 75234
Texas,South 4738 Cotton Belt (210) 661-5497San Antonio, TX 78219
Texas, Southeast 4301 S. Pinemont Ste 114 (713) 690-8700Houston, TX 77041
Washington 660 Industry Dr. (425) 575-3090Tukwila, WA 98188
West Virginia P.O. Box 1666 (304) 327-3594Rte. 2, Box 1Bluefield, WV 24701
APPENDICES
Page 74
APPENDICES
Figure 11: Parts Needing Periodic Maintenance
Step Chain
leveling Arm Pin
Pedal Arm Shaft
Spring Pulley Shaft
Page 75
APPEN
DICES
Figure 12: Final Assem
bly - Left, 4600 PTMain Gable 21417
Handl8i1 Assanbly lsft -18J16-03
21192 4X22036 4X22026
SlrapChain 2 X 20199
221B1 22070 22075
1S!1l~2175 ~ \ AllIIrn.1Dr
1T~il: P,II&y 2 X 22EK1 - ~21~
EJ ~ -7 2x 22191 2202
2 X 22030 21592-05
Section B-B Black,
Wh' :2075
4X22075 / Power Con nector Section G-G 24307
X 221B1
,24271 Bl8cillt 24666-03
Page 76
APPEN
DICESFigure 13: Final A
ssembly - Right,4600 PT
ยฅ2~Chain, =rLink
Shock We,nt 2 x 201 III
SIIlcsr1Wl1 Console Braclet ~ConSOlg Braclet Rght-1!1Xll.Q3 1sft-111D7.Q3
1E1Jl7
UPlllr Handles 2 X 1=0 1Wl2.Q3 "'-'L
221
22032 24271 2X22075 Bracket 24666-03
ll9tail H
21419
Black (Resistor 10 B+)
:15\lO-03 Belt 21529 4 X 22047 4 X 22026 4 X 22036
Black (PowerConn9CtDr 10 GID,nd)
Spring Pulley 2 X 2151 \I W,,-,her 2 X 22142 Snap Ring 2 X 21462
2 X 24164 2X21774 2 X 22326
Tach B+
Black (Resistor 10 GID,nd)
'p){2ยฎ'
Black (Main Cable 10 GID,nd)
BI,e(Main Cable BlDINn 10 Tach) \ (Main Cable
,jo F .. kl)
Whi1ll (Main Cable 10 Power Con nec1Drj
Main Cable21417 '::"::.::
..
Page 77
APPEN
DICES
Figure 14: Final Assem
bly - Left, 4600 CLMoi, cab .. 21415
o
Ha,d .. il Assanbly lsft-lI1l16.Q3 222,
22036 2 x 22913 3 x 2200 22175
Speed So,sor
~1446
22075 12Ql3 /22070
P"1oy 21Sl7
B
I'oNerCo)4tlOl Boonl (PCB) 24!113
22191 Sectb, B-B
Speed Se,sor Disk 22517
2x 2&M12
!BSV 2 x20157
21448
G ... , (PawIlrCOO'OC1Dr -13Sl7) IIlch ... isg"""d, Wh",,(l'oNerConnOC1D~
III PCB Nook I,..." Block
(I'oNerConnOC1D~ III PCB
21616 ~2D75 U x22Ql3 B18ciGt 24666.Q3 ~.-PaNarConntiE1Dr ) I ~~13Sl7
22032 Section E-E
Sectb, G-G
Page 78
APPEN
DICESFigure 15: Final A
ssembly - Right, 4600 CL
s~""r 111111 Console Bracl<lt Console Bracl<lt lsft-1 EDl7.al Right-1!1m.al 111117
2X111110~~ UpporHandleAsssnbly-1'I ~ 111112.al FI ~ ~ '"
Handla;1 Asssnbly Right -1!1l17.al
221112 24171 2 x 22075 2'1e66.al
22070 22C!1l '22075
:2347 21IlB
B.~ 21529 4 x 22047
4x22026 4x221ll6
2 x21462 2 x21519 2 x22143
2 x 22326 2 x 21774 2 x 24164
2 x22!Bl 21449
Wh;1BI8+) 1oR:B
Black BaI1llI'( 1-) 1oR:BI-)
8+
Black I Rosis1or21447) 1oR:B
Blk& Whilll
Ao~
BlONn IAo~) 1oR:B
. I'oN9r Con noc1or 13EB7 """,,",ContlDl Ba"d IR:B) 10 R:B
.'
Page 79
APPEN
DICES
Figure 16: Covers - 4600 PT/CLBotI!rn Shiekl HIll1 ScIllW 2 X 22276
UPJIll' left COler 1f1Jl5-OO
loN9r left CcMlr 4faJ PT-11ml-OO 4faJ CL-1!IE1-OO
A
Console Assembly
4X24877 4X22138
Site Handlail Assembly Rig ht -1I1l1].111 left-111l1 s.al
Upper RightCoillr 1lll!4-OO
loN9rRightCcMlr 4faJ PT-111E2-OO 4faJ C L -111Bl-OO
Handlail Adaplllr 2 X 2(674
X 22rJl7 2X22116
R9ading Rack :2775
1!ml
Pala I Pad Set 1!1E4
Section A-A
Page 80
APPEN
DICES
Figure 17: Pedal Arm
Assem
bly & First Reduction Shaft A
ssembly
(4600/4400 PT/CL, 4200 PT)
lsft - llB1l.al Right -IClHl.al
First Reduction Shaft 21Sl1
washer
~~ p""",-m Nssdl9 BIIoring 2 X 24747
washer 21366 ~al 2X22140
lsft -lcml.al Rilht -I!B12.al Pedal Arm Assanbly
lsft Pedal Arm shown aSSGmbl9d
23:
21Sl1_ A3719
24747
2cm;
1657
21657 22037
S9ction F-F (Flan all Final Assanbly dlawingsj
:9I:Sc_ 22037
Tia nsmission SplllClolt 2cm;
FilS! Reduction ShaftAssanbly Exploded V'eN
..
Page 81
APPEN
DICES
Figure 18:Drive Shaft A
ssembly &
Eccentric Hub A
ssembly
(4600/4400 PT/CL, 4200 PT)
Hub Assombly 10400
8mnlli: Hub Assombly 24817 IExplcdod viowl
I'oly-V Pulloy 2'Klll
Thrust ileoring ~A4X201!B
~RighIDriv9 ThrustWosiler ~ SPIOCi&t BX 20197 ~ ~ l00B!
20197 20200
201~ 20197 l00B2
2X201$
20197 201!B 20197 J
10400
20197 201!B 20197
FIB"'"
2 X 201$
2!l7I!5 Soclion D-D
IFlmlall Final Assombly dIBwingsl
"
Driv9Shaft 10485
Driv9 Shaft Assombly IExplcdod viowl
2363B~!tll 2'Klll / Ii I~ Al530
21&D{~. r 23631!./~23354
Sectio. e.G IFtan all Rnol AssomblydIBwingsl
{
Page 82
APPEN
DICES
Figure 19: Final Assem
bly - Left, 4400/4200 PTMain Cabl9 4400 PT ยท21417 42lD PT ยท21403
NllCkAssanbly w/Grips 24fDl-lll
2X21192
Section EยทE
22075 BllIclai: 4271
NllCk Insert 21515
22UZ L1 }4Ef6-1ll /
2 x 23CE4:::::-t:;rl l1J 22003
2 x 135l1l~ ,,f~15l1l 22070
4X22003
4X22075
2x2!il70 ~ 2217i/(22075
Load IllS' r QAltElma1Dr 22930 ,., Puliay
220351' rt/ 21587 3 x 22047 2 x 22!Bl
Fill ~ '\ ~ I '22ClZS 1/ ~ 2~-Ill 2x22191 21448 2 x 22030
Section BยทB
Black (PcwgrConnllC1D~
Whilll1D Ground
(Pcm9r Con nllC1D~ 1D Main Cabl9 22075
G!1lQn A
24271 BllIclai: 24Ef6-1ll
(PcwgrConn~~~ 1DChassis Gro~ ~~
Pcm9rConnllC1Dr 24307
Section GยทG
Page 83
APPEN
DICES
Figure 20: Final Assem
bly - Right, 4400/4200 PT
Nsck Asssnbly w/GriJII 24al3.()3
Drive Chain 22347 MaS19r Unk 2!XIB
2 x 20188 2 x 20157 2 y,roM
Black (R9Sis1D~ 1oB+
Black (I'ctN9rConnsc1o~ 10 Ground
Be~ 529
2 x 24164 x 21774
2 x 2232B
Ground
Tach
Whitll
Black (Rssis1D~ 10 Ground
Black (Main Cable) 10 Ground
(Main Cable) Main Cable 10 PoNsrConnsc1or 4400 PT -21417
4200 PT -21403
Page 84
APPEN
DICESFigure 21: Final A
ssembly - Left, 4400 CL
2 x 23054 2x25079 2 x 135l1J Lead lIlSisIor 21447
22031
222 u=::;;or:::r:Jl II I I p II
22075
S JlIlIld sansor 21446
~ 22070 22CBl
~PUIIay "
21597
Battery bl8C9~ I F ~ I
21::'IS8a ~s~ ~ H ~ I '1 I'cwsrContlO1 Balld (R:B) " ';SJlIlIld sansordisk
24!1l3 " u/l nl \ 2211;11 :Jm.lor' 22(91 \ 2~029 22517
2 2 X 20157
I II ~ 21!i12.Q5 22030
Neckinsart 21616
4x22075 / 4x22CBl
Section E-E
Section B-B
VVbH9(l'cwsrConnec\o~ Gl99n (I'cwsrConnec\o~ 10 R:B loCbassis GlOund / Black(l'cwsr
Connec\o~ 10 R:B
Bl8cllilt 2461i6.1Jl
~_---===-~'~"22032 Section G -G 2 x 22075
Page 85
APPEN
DICES
Figure 22: Final Assem
bly - Right, 4400 CL
14123 3 x 231154 \ \ -
21489
2 x 20188 SlIIpchain 2 x201!!l
,
ยท0ยท
NeckaSSGRlbly wI grips 241m -03
Main Cabla 21415
White (B+) 10 PCB
22032 24271 2 x 22075 241i1i6-03
22070 22CB1 2 x 22075
22347 2CDB
Black(-) 10 PCB
B+
21529 Whilll(+) 10 PCB
4x 22047 4x 2202& 4x2203&
2 x 21462 2 x21519 2 x 22143
2 x 2232& 2 x 21774 2 x 241&4
B lac k (Resis1o~ 10 PCB
FieU White (Resis1o~ 10 PCB
BltMln (FEU) 10 PCB
PowaiControl Beald (PCB)
1 Black&. Whi1e(l'oINerConnecto~ 10 PCB
Page 86
APPEN
DICESFigure 23: Covers - 4400 PT/CL, 4200 PT
laNar Right Caver 4400 PT-ZlCE7.(]l 4400 C l-Zl[ffi.(]l 4200 PT-24!B1.(]l r1/-I+;1--II;Y
Consol9 AssImb~
Riv9t 5x24757
Riv9t 8x24757
NGckCaver Right -2151O.(]l~ left -21511.(]l
laNarlsft Gaior 4ยซll PT-ZlCBI-Ill 4ยซll C l-27CES.(]l 42ID PT -24!1!1.(]l
MainC8bl9-N 24323
H<II rt Ra1ll Reooiver (Net ava i Ia bl9 on th.II200 Pl] 2511'ยฃi ~
fas1lln.r, Loop (ToCCl'O~ 22919
NGck Grarrnot 21578
Riv9t "'~ 4x22CES
l.a:m
Clip 5x24323
fa_.r. Hook (To Reooive~
~\U 22918
Page 87
APPENDICES
Figure 24: Cover Removal
1. Rsnove 4 fastaners and slide mid cover back
3. Rsnove 2 fastaners, ca lIIIu Ily S plaid the botIan covers ajllrt, and SEljlllalll the botIan cover fltJll the flame
Console
t Console Knob
~ ~ 2. 4SIXJ PTICL: RsnoveBfastaners and SElpllatB neck covers
44fll/4200 PTICL: Neck covers slide up in one piece
r BotIxm cover
Page 88
Figure 25: Cover fasteners
APPENDICES
Cover Fastener
cover~
Frame TUbe~
Fastener Removal (23853)
=
Tool
Removal Tool Fastener